Composition for application to a surface

ABSTRACT

Compositions, methods, apparatuses, kits, and combinations are described for permanently or temporarily re-designing, decorating, and/or re-coloring a surface. The compositions useful in the present disclosure include a décor product that is formulated to be applied and affixed to a surface. If desired, the décor product may be substantially removed from the surface before being affixed thereto. If a user desires to remove the décor product, the décor product is formulated to be removed by a number of methods including, for example, vacuuming, wet extraction, chemical application, and the like. If the user desires to affix the décor product to the surface in a permanent or semi-permanent manner, the décor product may be affixed to the surface by applying energy thereto in the form of, for example, heat, pressure, emitted waves, an emitted electrical field, a magnetic field, and/or a chemical. The décor product may also be utilized in the form of a kit or in conjunction with a design device, such as a stencil, to control the application of the décor product to create, for example, a pattern on the surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent Ser. No. 11/447,439,filed Jun. 6, 2006, which claims the benefit of U.S. ProvisionalApplication Ser. No. 60/687,953, filed Jun. 7, 2005. Each of theseapplications is hereby incorporated herein by reference in its entirety.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENTIAL LISTING

Not applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

Enhancement of surfaces that may be permanently or temporarilyre-designed, decorated, and/or re-colored is disclosed herein.

2. Description of the Background of the Invention

Improving the aesthetics in homes has long been practiced by manyconsumers. There is a plethora of home products and techniques forcleaning surface areas of soft surfaces such as carpets, rugs,draperies, curtains, upholstery, and the like. However, for more sulliedand/or worn surfaces, subtractive processes (for example, a process thatchemically or physically removes something from the carpet, such ascleaning or shaving) cannot truly restore the surface to its originalstate; this is often very frustrating for consumers. Oftentimes, spotsand stains reappear after treatment.

Additive processes (for example, a process that layers, covers, or maskssomething undesirable underneath) and techniques for improving theaesthetics of surfaces include painting, faux painting, stenciling,bordering, wallpapering, tiling, wainscoting, paneling, decorativeplastering, adding appliqués (for example, pictures, cut-outs, stickers,or the like), laminating, and molding (for example, crown, shoe, andchair) are also known. However, these products and techniques have notbeen applied to soft surfaces such as carpets, rugs, draperies,curtains, upholstery, and the like.

In some instances, color of worn, faded fabric is restored orrejuvenated with a composition containing water soluble and/or waterdispersible polymers and a surfactant capable of forming a bilayerstructure to provide a more durable color restoration and/or colorrejuvenation benefit that lasts at least after one washing cycle,preferably at least after two or more washing cycles. The compositionmay be applied to the fabric by a spray container.

In other instances, a method of redyeing partially bleached fabric orgarments includes dyeing the fabric or garment with a background colorand then gathering an area to restrict access to further reagents. Thegathered area is then bleached to remove the background colors from thearea outside the gathered area and then the bleached areas are redyedwith a second color.

In yet further instances, a digital printing device has a rotatablewheel, a liquid dispenser for depositing a liquid paint, ink, or dye onthe wheel along an outer edge, and an air jet positioned adjacent theouter edge for removing the liquid from the outer edge and directing theliquid toward a print medium as the wheel rotates through the air jet. Aplurality of devices is used to produce a full color digital image.

SUMMARY OF THE INVENTION

According to one aspect of the present disclosure, a décor productcomposition includes an interactive sensory element and a décor particleincluding a homogeneous mixture of a first additive and a polymerselected from the group consisting of a polyolefin, a polyurethane, anacrylic, an acrylate, a polyacrylate, a polyamine, a polyamide, apolyamid, a polyimide, a polyether, a polystyrene, a polycarbonate, apolysulfone, a polyester, a polyalkyleneoxide, a polysiloxane, apolysulfide, a polyethyleneimine, a polyglycoside, a cellulose, a wax, aparaffin, a phenolic, an elastomer, a vinyl, a hot melt adhesive, ahydrophilic polycarbodiimide, a polysaccharide aldehyde derivative, abismaleimides, a silicon, a soya oil, a linseed oil modified alkyd, acopolymer, a homopolymer, and mixtures thereof. The composition furtherincludes an optional second additive and a liquid carrier. The first orthe second additive includes at least one of a colorant, a surfactant, acurative, a flow additive, an odor eliminating agent, an odor absorbingagent, a bactericide, a miticide, an insecticide, a pesticide, or afungicide.

According to yet a further aspect of the present disclosure, aliquid-based décor product composition includes a colorant mixed with anadherent compound comprising at least one of a thermoplastic polymer ora thermoset polymer, an additive, and an interactive sensory elementincluding at least one of an illuminating effect or an olfactory effect.The adherent compound is soluble in at least one of a hydrocarbon, analcohol, a glycol ether, a nitrated solvent, a chlorinated solvent, aketone, an ether, an ester, an amine, benzyl acetate, a phenol, apolyvinyl alcohol, an organic sulfone, and a sulfoxide.

According to still another aspect of the present disclosure, a décorproduct for imparting a colorant to a surface includes a first layer, asupport layer disposed on the first layer and comprising an adherentcompound, and a décor product composition associated with the supportlayer, the décor product composition comprising an optional interactivesensory element and particles comprising a colorant and a polymer. Theadherent compound at least one of: 1) temporarily adheres the particlesto the first layer; 2) temporarily adheres the particles to the surface;and 3) permanently adheres the particles to the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of one possible method of applying a décorproduct to a surface;

FIG. 2 is a photomicrograph of applied décor particles on a surface;

FIG. 3 is an illustration of one possible method of affixing a décorproduct to a surface;

FIG. 4 is a photomicrograph of a décor product affixed to a surface;

FIG. 5 is a trimetric view of a design device incorporating multiplelayers including support layers according to one embodiment;

FIG. 6 is a cross-sectional view taken generally along the lines 6-6 ofFIG. 5 depicting the design device;

FIG. 7 is a plan view of a design device having a peripheral design aswell as a cutout portion according to one embodiment;

FIG. 8 is a perspective view of a peg that may be used in a method fororientating a design device on a surface according to one embodiment;

FIG. 9 is a perspective view of a layout tool used to orient pegs on asurface according to one embodiment;

FIG. 10 is a perspective view of pegs arrayed on a surface according toone embodiment;

FIG. 11 is a partial cutaway trimetric view a stencil-mounted peginterfacing with a second peg arrayed on a surface according to oneembodiment;

FIG. 12 is a flow diagram illustrating a method of applying a design toa carpet;

FIG. 13 is plan view of a design device for use with the method of FIG.12;

FIG. 13A is a bottom plan view of the design device of FIG. 13;

FIG. 14 is a cross-sectional view depicting an alternate embodiment ofthe design device;

FIG. 15 is a cross-sectional view taken generally along the lines 15-15of FIG. 13 depicting an alternative embodiment of the design device;

FIG. 16 is an isometric view of a border design device, having acolor-coding strip thereon, for use with the method of FIG. 12;

FIG. 17 is an isometric view of a corner design device, having acolor-coding strip thereon, for use with the method of FIG. 12;

FIG. 18 is an isometric view of a first end design device, having acolor-coding strip thereon, for use with the method of FIG. 12;

FIG. 19 is an isometric view of a second end design device, having acolor-coding strip thereon, for use with the method of FIG. 12;

FIG. 20 is a plan view of a placement of the corner design device ofFIG. 17, according to a set of instructions;

FIG. 21 is a plan view of a placement of first and second border designdevices of FIG. 16 according to a set of instructions;

FIG. 22 is a plan view of a placement of the first and second end designdevices of FIGS. 18 and 19, respectively, according to a set ofinstructions;

FIG. 23 is a plan view of a décor product affixed to a carpet accordingto the placement of the design devices as disclosed in FIGS. 20-22;

FIG. 24 is a grid pattern for use with one or more design devicesaccording to the method of FIG. 12; and

FIG. 25 is an illustration of a consumer aid according to oneembodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present disclosure is directed to compositions, methods,apparatuses, kits, and combinations, for permanently or temporarilyre-designing, decorating, and/or re-coloring a surface. While severalspecific embodiments are discussed herein, it is understood that thepresent disclosure is to be considered only as an exemplification of theprinciples of the invention, and it is not intended to limit thedisclosure to the embodiments illustrated.

For example, a composition useful in the present disclosure includes adécor product that is formulated to be applied and affixed to a surface.As discussed more fully below, if desired, the décor product may besubstantially removed from the surface before being affixed thereto. Ifa user desires to remove the décor product, the décor product isformulated to be removed by a number of methods including, for example,vacuuming, wet extraction, chemical application, and the like. If theuser desires to affix the décor product to the surface in a permanent orsemi-permanent manner, the décor product may be affixed to the surfaceby applying energy thereto in the form of, for example, heat, pressure,emitted waves, an emitted electrical field, a magnetic field, and/or achemical. The décor product may also be utilized in the form of a kit orin conjunction with a design device, such as a stencil, to control theapplication of the décor product to create, for example, a pattern onthe surface.

Any surface is contemplated to which the décor product may be appliedand/or affixed, including, for example, soft surfaces such as carpets,rugs, draperies, curtains, upholstery, and the like. In addition, thedécor product may be applied to hard surfaces as well, including, forexample, wood, metal, ceramic, glass, a polymer, a hard floor tile, apainted surface, paper, masonry material, rock, a fiber/compositematerial, rubber, concrete, and the like. It is contemplated that thedécor product may be applied to any prepared surface, including, forexample, pre-dyed, post-dyed, pre-manufactured, and post-manufacturedsurfaces. Further, the décor product may be applied during themanufacturing process of a particular good or object that includes asurface in which the décor product may be applied. Surfaces to which thedécor product may be applied and/or affixed may be substantially dry,substantially wet, moist, or humid depending on the particular décorproduct utilized. Further, a décor product of the present disclosure maybe applied to a substantially flat, smooth, and/or level surface or anyother surface including rough, bumpy, non-smooth, stepped, sloped,slanted, inclined, declined, and/or disturbed surfaces.

Examples of carpets to which the décor product may be applied and/oraffixed include modular tiles and panels such as Milliken LEGATO®,Milliken TESSERAE®, INTERFACEFLOR™, Tandus/C&A floorcovering, and frommanufacturers such as Mohawk Industries and Shaw Industries, Inc.Additional examples of carpets include broadloom carpets, cut pile(velvet/plush, Saxony, frieze, shag), loop pile (level loop, multi-levelloop, and Berber), and cut and loop pile (random sheared and tipsheared) carpets. Additional examples of soft surfaces to which a décorproduct may be applied and/or affixed thereto include, for example, arearugs (hand woven or machine woven), draperies, curtains, upholstery, andcellulosic materials, among others. Constituent materials of candidatesoft surfaces include, for example, natural fibers such as wool andcotton, or synthetic fibers such as nylon 6, nylon 6-6, polyester,polypropylene (olefin), and acrylic, among others.

Décor products of the present disclosure may be formulated, designed,produced, manufactured, applied, removed, and/or packaged by anyformulaic, chemical, and/or physical preparation appropriate for thespecific embodiment desired, as would only be limited by the inherentnature of the constituent ingredients. Illustrative formulations of thedécor products include a solid that may be dissolved or dispersed in aliquid to make a liquid-based décor product, a liquid carrier, anemulsion, a suspension, a colloid, a sol, a dispersion, a solution, agel, a paste, a foam, a powder, a spray, a tablet, a solid, a gas, adiluent such as water or other solvent, an aerosol, and combinationsthereof. Examples of chemical preparations include polyesterpolymerizations, latex aggregation, chemical milling, andmicroencapsulization, and other methods known to those skilled in theart. Physical preparation may consist of physically grinding the décorproduct ingredients or other means known to those skilled in the art.Décor products may be either synthesized from a molecular route, inwhich polymer resin molecules incorporate colorants, dyes, and/orpigment particles at the molecular scale, such as in the method ofmanufacture used in chemically prepared toners, or the resin and pigmentparticles may be physically blended together and crushed to appropriatesize by mechanical means known to those skilled in the art.

The décor product may be chosen based on any number of criteria,including, but not limited to the surface type, condition, and/orcomposition to which the décor product is applied and/or affixedthereto. Further criteria for choosing a décor product include desiredlightfastness, color range, intensity, uniformity of colorant, and/ordesired curative and/or fixation properties of the décor product.Additional choice factors include enhancement of the appearance and/orfeel of the carpet or other surface, masking a stain (for example, bylaying an area rug-type décor product), or value adding to a surface(for example, to extend the life of a carpet).

A décor product useful in the present disclosure may comprise any one orcombination of a colorant that includes, for example, a coloring agent,a dye, an ink, a toner, a paint, a patch, a carpet glitter, afluorescent material, a composite thermal transfer sheet, a particle, acoating, a pigment, a luminescent material, a microparticle,magnetically responsive particles, a virtual colorant which is notcolored until activated, and/or a colorant with hybrid pigmentmolecules, an additive, and combinations thereof. Illustratively, adécor product composition contains a colorant in an amount of greaterthan about 0.01% or less than about 95%, or between about 0.01% to about70%, or between about 0.03% to about 15%, or about 0.05% to about 10%,or between about 0.1% to about 5%, of the total weight of the décorproduct.

Any imaginable color of the décor product is contemplated in the presentdisclosure including, but not limited to cyan, yellow, magenta, black,green, orange, violet, blue, red, purple, white silver, gold, metallic,clear, neutral, or non-neutral, and any combination thereof. Color maybe imparted to the décor product by combining varying amounts ofmonochromic décor product particles of different colors or by combiningvarying amounts of polychromic décor product particles having differentcolors. Further, a specific décor product color may be achieved bycombining predetermined amounts of monochromic particles of differentcolors or by combining predetermined amounts of polychromic décorproduct particles of different colors. In this way, all imaginablecolors may be incorporated into the décor product.

The décor product may also comprise a virtual colorant that is notapparently colored until activated and/or deactivated. As an example,phosphorous containing colorants may be incorporated into a décorproduct to add special effects via fluorescent properties. Further,virtual colorants may add special visual effects by altering theapparent décor appearance according to light intensity, light angle,angle of view, and/or illumination of the décor product. Such activationof the virtual colorant includes, for example, exposing a phosphorouscontaining virtual colorant to various wavelengths of light. As known tothose skilled in the art, phosphor containing compounds luminesce orfluoresce when exposed to light. When exposed to visible light, phosphorgives off visible white light. Exposure of a phosphor containing virtualcolorant to sunlight may also make whites appear brighter because theultraviolet light in sunlight gives the appearance that the whites inthe virtual colorant glow brighter than “normal” white. When exposed toblack light from, for example, a substantially ultraviolet-A wavelengthemitting light bulb, phosphorous containing compounds glow with a purplehue. Black light can be provided, for example, from a tube black lightthat is basically a fluorescent lamp with a modified phosphor coating.This modified coating absorbs harmful shortwave ultraviolet-B andultraviolet-C wavelengths and emits ultraviolet-A wavelengths. The tubeof the tube black light is black so as to block most visible light whileemitting mostly long-wave ultraviolet-A wavelengths. Another useful typeof black light includes black light provided from an incandescent blacklight bulb. The black light emitting incandescent black light bulb issimilar to a normal household light bulb, but incorporates a filter thatabsorbs most visible light while emitting infrared and ultraviolet-Alight.

In a further embodiment, décor products containing virtual colorants mayserve as night lights, indicate routes from room to room, exit routes,and/or escape routes.

Any number of products may be used in the décor product to impartreversible coloring to a surface. Such products include, for example,dyes, toners, powder paints, inks, and combinations thereof. Examples ofdyes that may be used include water-based dyes such as LIQUIDTAINT™ andVERSATINT® by Milliken Chemical Company. Examples of toners that may beused include reactive toners such as powder toners. Examples of usefulpowder toners include those that are available from SawgrassTechnologies, Inc., such as NATURA™ powder toners, as well as theformulations and/or compositions individually disclosed in the U.S.patents and published patent applications provided below in Table No. 1.

TABLE NO. 1 Powder toner formulations. Patent/Publication No. U.S. Pat.No. 6,649,317 U.S. Pat. No. 6,673,503 U.S. Pat. No. 6,618,066 U.S. Pat.No. 6,840,614 U.S. Pat. No. 6,849,370 U.S. Pat. No. 6,887,640 U.S. Pat.No. 5,734,396 U.S. Pat. No. 5,488,907 U.S. Pat. No. 5,487,614 U.S. Pat.No. 5,601,023 U.S. Pat. No. 5,642,141 U.S. Pat. No. 5,830,263 U.S. Pat.No. 5,640,180 U.S. Pat. No. 5,522,317 U.S. Pat. No. 5,431,501 U.S. Pat.No. 5,555,813 U.S. Pat. No. 5,575,877 U.S. Pat. No. 5,590,600 U.S. Pat.No. 5,644,988 U.S. Pat. No. 6,425,331 U.S. Pat. No. 6,439,710 U.S. Pat.No. 6,450,098 U.S. Pat. No. 5,246,518 U.S. Pat. No. 5,302,223 U.S. Pat.No. 5,746,816 U.S. Pat. No. 6,341,856 U.S. Pat. No. 6,152,038 U.S. Pat.No. 6,348,939 U.S. Pat. No. 6,402,313 U.S. Pat. No. 6,486,903 U.S. Pat.No. 6,540,345 U.S. Pat. No. 6,105,502 U.S. Pat. No. 5,326,872 U.S. Pat.No. 5,177,209 U.S. Pat. No. 6,103,041 U.S. Pat. No. 6,447,629 U.S. Pat.No. 5,248,363 U.S. Pat. No. 6,686,314 U.S. Pat. No. 6,631,984 U.S. Pat.No. 6,894,087 U.S. Pat. No. 6,794,426 U.S. Pat. No. 6,759,450 U.S. Pat.No. 6,737,450 U.S. Pat. No. 6,710,102 U.S. Pat. No. 6,664,311 U.S. Pat.No. 6,348,679 U.S. 2005/0123743 U.S. Pat. No. 6,849,837 U.S. Pat. No.6,649,888 U.S. Pat. No. 6,617,557 U.S. Pat. No. 6,600,142 U.S. Pat. No.6,812,334 U.S. Pat. No. 6,812,445 U.S. Pat. No. 6,872,444

Toner particles useful in the present disclosure may have sizecharacteristics of about 90% or more of the particles having a size lessthan about 100 microns, or less than about 25 microns, or less thanabout 10 microns, or from about 0.1 to about 50 microns, or from about 1to about 20 microns, or from about 3 to about 10 microns, or fromgreater than about 750 nm to about 100 microns, or larger or smallerparticle sizes depending on the desired application. In one embodiment,the toner particle melting point ranges from about 60° C. or less, toabout 150° C. or higher, or from about 60° C. to about 275° C., or fromabout 25° C. to about 110° C., or from about 80° C. to about 100° C.

Other toners, compositions, additives, and curing processes useful inthe present disclosure are disclosed in, for example, U.S. Pat. No.6,850,725. Yet other toners, compositions, additives, and curingprocesses useful in the present disclosure are disclosed in, forexample, U.S. Pat. No. 6,713,222. Still other toners, compositions,additives, and curing processes useful in the present disclosure aredisclosed in, for example, U.S. Pat. No. 6,680,153.

Examples of powder paints that may be useful include those with epoxy,polyester, polyurethane, and hybrid chemistries either as additives oras décor particles, described hereinafter. An example of a hybridchemistry contemplated for use is an epoxy-polyester hybrid, which isroutinely used in the reactive powder coating industry. Typical particlesizes for powder paints can range, for example, from greater than about20 microns to about 50 microns; however, for purposes of the presentdisclosure, larger and smaller sizes are contemplated and may depend on,for example, the reversibility and/or affixation properties desired.Typical powder paints may have melting point temperatures from aroundabout 107° C. to about 163° C. to about 302° C.; however, lower andhigher temperatures are contemplated within the present disclosure.

Further, the décor product may comprise a colorant with a hybrid pigmentparticle. An example of a hybrid pigment particle may be, for example, adye and pigment combination. In this embodiment, the pigment moleculemay coat a fiber surface, while the dye molecule penetrates the fiber.

In another embodiment, the décor product is formulated to include one ormore thermoplastic resins, thermoset resins, colorants, additives,and/or liquid carriers. Examples of thermoplastic resins includepolymeric materials such as polyesters, unsaturated polyesters,styrene-butadiene copolymers, polyurethanes, styrene-acrylates, and/oracrylics. Illustratively, thermoplastic and/or thermoset resins that maybe useful in the present disclosure have a melting point of about 260°C. or less, for example.

In another embodiment, the décor product may include encapsulated décorproduct particles including, for example, nanoencapsulated,microencapsulated, macroencapsulated, and compartmentalized particles.Illustratively, microencapsulated décor product particles may include,for example, one or more outer shells, one or more inner compartments,one or more colorants, and/or one or more additives. The one or morecolorants and/or one or more additives may be in the same or differentcompartments. This microencapsulated décor product particle may, forexample, provide advantages such as to lengthen the shelf-life of thedécor product, enhance décor product compatibility with deliverysystems, promote bonding of the décor product to the surface, promoteremovability of the décor product from surfaces before and/or afterfixation, and/or promote thermal fixation of the décor product to asurface. Other benefits associated with encapsulation of compoundsinclude, for example, timed release of compounds, and buffering systems,among others known to those skilled in the art, and are contemplated inthe present disclosure. The compartmentalized and/or microencapsulateddécor product particles may have multiple distinct regions of equaland/or differing sizes containing the same and/or differing substances,such as, for example, one or more solids, one or more liquids, one ormore gases, and/or combinations thereof. As an example,microencapsulation technologies useful in the present disclosure areprovided by Microtek Laboratories, Inc.

In a further embodiment, the décor product may include a removable paintand/or surface coating. In this regard, the décor product may beremovable via wet-chemistries, such as ammonia-based, acid-based, and/orwater-based chemistries. Illustratively, the décor product may be aliquid with one or more surfactants, zinc oxide, and/or one or morecolored pigments. The décor product of the present embodiment may beremoved by, for example, a weak acid, a buffering agent, a mildlyalkaline solution, a polar or non-polar solution, a detergent, a soap,an alcohol, and/or a solid compound, and/or combinations thereof.

Illustrative ammonia-based chemistries useful in the present disclosureinclude those supplied by Missouri Turf Paint (for example, TITAN™Removable), or by Pioneer, or by Sports Coatings, or by SpecialistGroup. Acid-based chemistries useful in the décor product of the presentdisclosure include those supplied by Remarkable Paint Company, andinclude, for example, those found in RE-MARKABLE® Paint. Additionalremarkable field paints useful in the present disclosure include thosedisclosed in, for example, U.S. Patent Application Publication No.2004/0127376. Other useful examples of remarkable field paints in thepresent disclosure include those disclosed in, for example, U.S. Pat.No. 6,653,265. Additional examples of strippable ammonia formulationsuseful in a décor product of the present disclosure include thosedisclosed in U.S. Pat. No. 5,041,488 and those that include susceptiblestyrene/acrylic compounds. Other useful water-based dyes andcompositions include those disclosed in, for example, U.S. Pat. No.6,834,589.

Water-based chemistries useful in the present disclosure include thosesupplied by Magic Colors Company (for example, Remove It Permanent PaintSystem). It is further contemplated that aqueous fabric paints and/orpaint systems may be useful in the décor product embodiments of thepresent disclosure. Examples of aqueous fabric paints useful in thepresent disclosure include, for example, Jacquard Products includingJacquard Textile Colors, DYE-NA-FLOW™, and NEOPAGUE™, Marabu-Textil madeby Marabuwerke GmbH & Co. KG, and SIMPLY SPRAY™ available from SunshineJoy Distributing. Wet-erase inks removable by solvents after short orextended periods of time that can be used on multiple surfaces are alsouseful in the present disclosure. Such wet-erase inks may incorporatewater-soluble binders, cellulose derivatives, and/or polyvinylpyrolidone.

Additional embodiments may incorporate dry erase inks, peelable and/orstrippable coatings, alkali soluble resins, and various value addingchemistries disclosed herein. Examples of dry-erase inks, compositions,and applicators thereof may include those provided by ITW Dymon, PilotPen Corp., Sanford Corp., Avery Dennison Corp., Binney & Smith Inc., andDainippon Ink and Chemicals, Inc. Other dry erase inks, compositions,and applicators that may be useful in the present disclosure includethose disclosed in, for example, U.S. Pat. No. 6,031,023.

Additional useful formulations of the present disclosure includepeelable and/or strippable coatings made by Spraylat International, LTD.In addition, it is contemplated that the décor product may include athermally releasable coating and/or blowing agent to aid in the removalof the affixed décor product. An example of thermally releasablecoatings and blowing agents useful in the present disclosure includesthose disclosed in, for example, U.S. Pat. No. 5,010,131. Other coatingsuseful in the present disclosure include nanoparticle coatingcompositions disclosed in, for example, U.S. Pat. No. 6,872,444.

In another embodiment, the décor product incorporates alkali solubleresin systems. Examples alkali resin systems include styrene/maleicanhydride, styrene/acrylic and methacrylic acid, isobutylene/maleicanhydride copolymers, and proprionic acid-modified urethanes. Alkaliresin systems useful in the present disclosure are available fromcompanies such as BASF Corp., Kuraray Co., LTD, Johnson Polymer, Rohmand Haas Co., Interpolymer Corp., Scott Bader Co., LTD, Sartomer Co.,and DSM NeoResins, among others. Examples of useful additives for alkalisoluble resin systems include divalent zinc salts. Other useful alkalisoluble resin systems are further disclosed in U.S. Pat. No. 6,147,041.Additional alkali soluble resin systems include, for example, thosedisclosed in U.S. Pat. No. 5,453,459.

Further embodiments of the present disclosure may incorporate valueadding chemistries including powder coatings, toner and/or inkchemistries, carpet stain removers and/or maskers, odor eliminatorsand/or absorbers, bleaching agents. Compositions and methods of carpetstain removing and/or masking useful in the present disclosure includethose disclosed in Attorney Docket Nos. J-4377A (U.S. Pat. No. 7,556,841granted on Jul. 7, 2009), J-4377B (US 2007/0089621A1 published on Apr.26, 2007), J-4377C (US 2006/0288499 A1 published on Dec. 26, 2006), andJ-4550 (U.S. Pat. No. 7,423,002 issued on Sep. 9, 2008). Further,technologies used in aftermarket carpet dyeing in the automotiveindustry may be useful in the present disclosure, including, forexample, the “Pro Dye System” available from Top of the Line. Anadditional contemplated chemistry includes ultraviolet radiationcross-linking agents that crosslink décor product particles inpreparation for affixation of the décor product to a surface or removaltherefrom.

In other embodiments, a décor product contemplated in the presentdisclosure may include one or more additives that may be incorporated,for example, during formulation, added post-formulation prior toapplication of the décor product to a surface, and/or after the décorproduct has been applied to the surface. Illustrative additives usefulin the present disclosure include, for example, a filler, a metallicparticle, an adhesive, a binder, a toner, a resin such as an acrylic, anacrylic latex, a polyester, a urethane, and/or an epoxy resin, acarrier, a wax, a charge additive, a protein, an overcoating lacquersuch as an ultraviolet initiator, an ultraviolet light absorber, anultraviolet stabilizer, an ultraviolet blocker, a stabilizer, athickening agent, anti-wicking additives, a dry powder, a surfactant, awetting agent, an emulsifier, a coating, a dispersing agent, a perfume,a fragrance, a pigment, a dye, a preservative, a solvent, a lubricant, afluidity improver, a flow additive, a humectant, a propellant (forexample, a pressurized gas or a hydrocarbon based propellant such asbutane and propane), an inorganic particulate additive, magneticallyresponsive microparticles, temporal emission agents, additives providinga safety benefit, additives providing a surface protection benefit,electrical additives, interactive sensory additives, a degassing agent,an antioxidant, a heat stabilizer, a wax, a silicone additive, acatalyst, a texturing agent, an electrical charge control agent, anelectrical conductivity agent, a processing aid, a dry powder of a metalsalt, a metal salt of a fatty acid, a colloidal silica, an inductiveingredient, and/or a metal oxide, and combinations thereof.Illustratively, a décor product composition contains an additive in anamount of greater than about 0.1%, or less than about 75%, or betweenabout 0% to about 50%, or between about 0.001% to about 30%, or betweenabout 0.01% to about 10%, or between about 0.1% to about 5%, of thetotal weight of the décor product.

An adhesive or binder may include resin particles chosen to exhibit aglass transition temperature that is lower than the glass transitiontemperature of resins employed in the color toners. Adhesives and/orbinders with lower glass transition temperatures may positively affectthe aesthetic feel of the décor after affixation. In addition, suchadhesives and/or binders may augment the stability of a compositionprepared as an emulsion and provide greater mechanical bonding of thedécor product to carpet fibers including, for example, elastomericmaterials including styrene/isoprene, styrene/butadiene, andisobutylene. Adhesives and binders may also be selected based on thereversibility on a soft surface, including, for example, nylon andpolyester carpets, before and/or after a curing step, such as, forexample, Alcoprint PTU (Ciba Geigy Corp.). A high level of retentionafter curing may also be desirable in certain applications. Examples ofadhesives useful in the present disclosure include polymeric resin andmay provide a laminating adhesive between a polymeric resin particleand/or between a soft surface and the polymeric resin particle. In oneembodiment, the polymeric resin, for example, a toner such as a cleartoner, may also act as an adhesive. Examples of adhesives and bindersuseful in the present disclosure include STYRONAL® ND 656, a styrenebutadiene copolymer latex from BASF Corp., and INCOREZ® W2450, aurethane/acrylic emulsion from Industrial Copolymers Unlimited in theUK. Other resins useful in the present disclosure include, for example,crosslinked terpolymers of styrene, acrylate ester, and acrylonitrileavailable from Zeon Chemical L.P., which include toner resins S-103C andS-111, and styrene-acrylic resins available from Sekisui Chemicals Co.LTD, including S-LEC resin that is based on a styrene and acryliccopolymer. Other resins useful in the present disclosure include, forexample, styrene/butadiene, styrene/butyl acrylate, styrene/2-ethylhexylacrylate, and styrene/butylacrylate resins available from Elikem,including those under the PLIOTONE™ trade name. Polyester resins mayoffer lower temperature fusing than styrene/acrylates orstyrene/butadiene resins permitting the application of less heat to thedécor product and/or the soft surface. Illustrative polyester resinsinclude thermoset polyesters, unsaturated polyester resins, such as,orthophthalic, isophthalic, dicyclopentadiene, and bisphenol A fumarateresins, and those available from, for example, Kao Specialties Americas,LLC. Polyurethane resins, including those based on an exothermicreaction of an organic polyisocyanate with a polyol, are also useful inthe present disclosure. Illustratively, a décor product compositioncontains an adhesive in an amount of greater than about 0.1%, or lessthan about 75%, or between about 0% to about 50%, or between about0.001% to about 30%, or between about 0.01% to about 10%, or betweenabout 0.1% to about 5%, of the total weight of the décor product.

Illustrative stabilizers include a benzophenone, a benzotriazole, asalicylate, a nickel organic, a monobenzoate, a formamidene, anoxalanilide and/or a phenol. Examples of an ultraviolet stabilizer thatprovides enhanced protection against ultraviolet light includes thosedisclosed in, for example, U.S. Pat. No. 6,152,038. Examples ofthickening agents useful in the present disclosure include thosedisclosed in, for example, U.S. Pat. No. 6,752,841. Examples ofanti-wicking additives useful in the present disclosure can be found inU.S. Pat. No. 5,116,682.

Another embodiment contemplated in the present disclosure mayincorporate one or more surface-active (surfactant) agents, for example,emulsifiers. The use of surfactants in the décor product may promotecolorant and/or filler wetting, as well as improve flow and leveling ofthe powder finish. In addition, surfactants promote substrate wet-outduring the cure reaction, which improves adhesion and corrosionresistance of the décor product. The addition of surfactants mayincrease the gloss and distinctness of images of the cured décorproduct, as well. The addition of one or more surfactants may act tostabilize the décor product formulation, as well as to assist insuspending the particles of a décor product formulation and attachingthe décor product to a surface. Surfactants useful in the presentdisclosure include ionic, nonionic, and/or cationic surfactants.Emulsifiers and/or emulsifying agents useful herein include ALCOPRINT™PTU from Ciba Geigy Corp., the JONCRYL™ series of emulsifying agentsavailable from Johnson Polymer, and others known to those skilled in theart including, for example, adhesive formulations and latexformulations. Other examples of suitable emulsifiers include sodiumlaurylsulfate, potassium laurylsulfate, or ammonium laurylsulfate,including, for example TRITON® 100(octylphenoxypolyethoxy-ethanol-polyethylene glycol). Illustrativeexamples of cationic surfactants include dodecyl ammonium chloride,dodecyl ammonium bromide, dodecyl trimethyl ammonium bromide, dodecylpyridinium chloride, dodecyl pyridinium bromide, and hexadecyl trimethylammonium bromide. Illustrative examples of anionic surfactants includealiphatic soap such as sodium stearate, sodium dodecanate, sodiumdodecyl sulfate, sodium dodecylbenzenesulfonate, and sodiumlaurylsulfate. Illustrative examples of nonionic surfactants includepoly-oxyethylenedodecyl ether, polyoxyethylenehexadecyl ether,polyoxyethylenenonylphenyl ether, polyoxyethylenelauryl ether,polyoxyethylene sorbitan monoleate ether, and monodecanoyl sucrose.Illustratively, a décor product composition contains a surfactant in anamount of greater than about 0.001%, or less than about 75%, or betweenabout 0.001% to about 50%, or between about 0.1% to about 30%, orbetween about 0.01% to about 10%, or between about 0.1% to about 5% ofthe total weight of the décor product.

A fluidity improver useful herein includes, for example, styrene resin,acrylic resin, finely divided hydrophobic silica powder, finely dividedtitanium oxide powder and finely divided aluminum oxide powder. Furtheradditives may serve as fiber wetting promoters, fiber drying promoters,fiber cleaners, and fiber cleaning promoters. A formulation of thepresent disclosure may also contain an inorganic particulate materialsuch as, for example, magnetite, ferrite, cerium oxide, strontiumtitanate and/or electrically conductive titania.

The décor product may include magnetically responsive microparticleswith or without colorant. In this embodiment, the décor product may beapplied using a static charge and/or magnetically directed force. As anexample, iron oxide and/or other magnetic particles known to those inthe art form a part of the formulation rendering the décor productmagnetically responsive. The magnetically responsive property may beused for further placement onto the fiber and/or for enhanced removalfrom the fiber and/or to aid with aesthetic considerations such ascreating designs and/or patterns.

Further, the décor product envisioned in the present disclosure may haveadditives designed to impart additional non-visual benefits such asfragrancing and aromatherapy. Further additives may include temporalemission agents, for example, short- or long-term emission agents, suchas spot cleaners and odor eliminators, and the like, and/or bioactiveagent additives such as bactericides, miticides, insecticides,pesticides, and/or fungicides, which are released over periods ofseconds to minutes to hours to days to weeks to months to years.

Further, the décor product may incorporate additives such as fireretardants and anti-slip agents. Further, the applied décor product mayserve to protect the surface areas to which it is affixed from stains,chips, dents, rips, blemishes, burns, splintering, abrasion, cuts, rust,oxidation, water damage, mold, and/or dirt. Further, the applied décorproduct may serve as an electrical insulator, for example, to reducestatic electrical charges.

In another embodiment, a décor product of the present disclosure mayincorporate interactive sensory elements that interact with one or moresenses of the user. Examples of interactive elements include moodlighting, sound (for example, music, indicative sound, or instructivesound), and scent (for example, fragrance emitters, deodorizers, and/orodiferous pet barriers only detectable by animals).

Illustratively, a formulation of a décor product, for example, anemulsion, contains on a weight to weight basis, at least one of: 1) asurface-active agent in an amount of greater than about 0.1%, or lessthan about 75%, or between about 0% to about 50%, or between about0.001% to about 30%, or between about 0.01% to about 10%; or betweenabout 0.1% to about 5%; 2) an adhesive agent in an amount of greaterthan about 0.1% or less than about 75%, or between about 0% to about50%, or between about 0.001% to about 30%, or between about 0.01% toabout 10%; or between about 0.1% to about 5%; 3) a colorant in an amountof greater than about 0.01% or less than about 95%, or between about0.01% to about 70%, or between about 0.03% to about 15%, or about 0.05%to about 10%; or between about 0.1% to about 5%; 4) an additive in anamount of greater than about 0.1%, or less than about 75%, or betweenabout 0% to about 50%, or between about 0.001% to about 30%, or betweenabout 0.01% to about 10%; or between about 0.1% to about 5%; and 5) thebalance water.

A clear toner may also be included in a décor product composition of thepresent disclosure in an amount equivalent to, for example, the amountof the colorant. For example, in a toner formulation having 10% byweight a colorant, an additional 10% by weight of the toner formulationcontains a clear toner. Illustratively, in a toner formulation withabout 0.5% w/w yellow colorant, about 0.4% w/w magenta colorant, andabout 0.2% blue colorant, the toner formulation also contains about 1.1%clear toner. In another example, an emulsifier contains about 100 gramsof water, about 1 gram of yellow NATURA™ toner, about 0.4 grams of blueNATURA™ toner, about 0.8 grams of magenta NATURA™ toner, about 2.2 gramsof clear NATURA™ toner, and about 0.33 grams of ALCOPRINT™ PTU. Anemulsion of the present disclosure may be made by mixing the variouscomponents of the emulsion for a period of time until the particles ofthe emulsion are coated with the emulsifying agent or agents. Thecoating of the particles may enhance the stability of the formulation.The mixing time depends on the particular components utilized in aformulation and can range from, for example, from about 1 minute or lessto about 48 hours, or longer.

In another embodiment, the décor product may be formulated as astain-removing and masking agent containing a base color such as a whiteand/or neutral color and/or other color onto which additional desiredcolors may be overlain. Illustratively, the décor product may contain apH neutralizing and/or adjusting pretreatment compound such as, forexample, a peroxide and/or a bleach, and/or a titanium dioxide-typeneutral color application. The décor product may further include astain-masking agent and/or coloring agent as disclosed herein. Anotherembodiment contemplates the application of a highly pigmented coatingthat has a white and/or neutral color that provides a mask and/or hidesa color difference (for example, a stain) on a surface. Further, anothermaterial with a color matching the bulk fiber of the surface (forexample, a carpet or textile) may be applied subsequent to the maskingof the stain.

In yet another embodiment, a décor product composition may have a glasstransition temperature (Tg) from below about 25° C. up to the meltingtemperature (Tm) of the surface substrate to which it is to be applied.In a further embodiment, the Tg ranges from about 45° C. to about 75°C., or from about 45° C. to about 60° C., or from about 45° C. to about70° C., or about 55° C. The Tg and Tm of a composition or a surfacesubstrate may be measured by methods known to those skilled in the artincluding, for example, dynamic mechanical analysis, thermomechanicalanalysis, and differential scanning calorimetry. Illustratively, Tg andTm values of décor products and surface substrates may be determinedusing a Model Q100 Differential Scanning Calorimeter (TA Instruments,Inc.) at a heating rate of 20° C./min.

In still another embodiment, the décor product composition has anImperial Chemical Industries (ICI) cone and plate viscosity of equal toor less than about 2,000 centipoises, or about 5 centipoises to about100 centipoises, or about 15 centipoises to about 50 centipoises, orabout 25 centipoises, or about 35 centipoises at about 150° C. to about200° C. The viscosity of a composition may by measured by methods knownto those skilled in the art, including for example, using aWells-Brookfield Cone/Plate viscometer distributed by Can-Am InstrumentsLTD and following methods as set forth in D4287-00 (2005) “Standard TestMethod for High-Shear Viscosity Using a Cone/Plate Viscometer,” ASTMInternational. Further, a Brookfield CAP 2000H Cone and Plate Viscometer(available from Brookfield Engineering Laboratories, Inc.) set at 750rpm for 25 seconds using a size six spindle may be used to measure theICI Cone and Plate viscosity of the décor product composition.

Application of the décor product contemplated in the present disclosuremay occur by any appropriate way that is compatible with the décorproduct formulation utilized. Illustrative ways to apply the décorproduct to a surface include the use of an ink jet printer, a jet dyeprocess, silk screening, and/or rotary printing. Further, the décorproduct may be applied and/or dispensed with and/or by a spray gun, asheet, a film, a matrix, a roller, a brush, a marker, a pen, a stampsuch as a self-inking stamp, a pump sprayer, a trigger sprayer, apressurized spraying device, a sponge, a squeegee, an airbrush, a fiberseparator, a dye applicator, a roller, piezoelectric or heat drivendelivery, a manual or electronic sifter, a powder “puff”, afelted/flocked brush, and/or a powder paint dispenser. The décor productmay be applied in a wet form, such as, for example, as a suspension oremulsion including, for example, a liquid-based solvent, a foam, aspray, a wet aerosol, or in a dry form, such as, for example, as apowder, a dry aerosol, and/or a powder with a gentle mist.

By way of example, one possible method of applying a décor product to aselected surface is generally depicted in FIG. 1. Here, a finger pumpsprayer 12 including a reservoir 14 for holding the décor product andfinger pump 16 is used to apply a generally cone-shaped dispersion 18 ofdécor product to a surface 20 such as a carpet. In this embodiment, byvarying the distance of the finger pump sprayer 12 from the surface 20and angle of the finger pump sprayer relative to the surface, the sizeand shape of the pattern 22 imparted to the surface may be varied. Inthis way, a preselected pattern may be imparted to a surface using a“free-hand” technique without a design device.

Additional examples of applicators and/or dispensers of the décorproduct of the present disclosure include, for example, an intermittentpressurized sprayer (such as PULL 'N SPRAY® liquid applicator marketedby The Scotts and Miracle-Gro Company), an actuator spray bottle, atrigger sprayer, a mechanical spray bottle, a pump and/or pump system, aliquid refill containing the décor product for a pressurized airchamber, an aerosol barrier pack containing the décor product with adriving chamber (with a propellant, for example, carbon dioxide or ahydrocarbon), and a liquid or gel chamber for containing the décorproduct where use would allow pressurized spraying with reducedpropellant release to the atmosphere or room being decorated by theuser. Other useful sprayers include those disclosed in, for example,U.S. Pat. No. 6,872,444.

Still further other ways to distribute the décor product include, forexample, a décor product impregnated sheet that contains entrapped dryor wet décor product particles that when wetted or otherwise activated,releases the décor product onto the surface. Another example includes adécor product impregnated sheet containing entrapped liquid thatreleases the décor product onto the surface upon pressure application orcontrolled puncture. A further example includes a décor productimpregnated sheet with liquid rolled or stamped thereon that promoteseven distribution of the décor product. Still another example includesan apertured or perforated décor product impregnated film that collectsand/or directs a releasing substance that once applied to the filmreleases the décor product onto a surface. Yet another example includesa décor product impregnated matrix containing therein and/or thereonentrapped décor product formulation that releases the décor product ontoa surface upon pressure, vibration, liquid transfer, heat application,and/or chemical means and/or by an electrostatic deposition device thatmeters an amount of décor product to be applied to a surface andprecisely lays the décor product on the surface.

Still further ways for application of the décor product include amultiple chamber system that mixes the décor product upon dispensing togive the desired décor product color or other characteristic, such asare exemplified in part by trigger release systems (for example, DLS100,DLS 200, or Versitech systems manufactured by Take 5, Anaheim, Calif.(www.take5net.com)), pump systems (for example, VERSADIAL® manufacturedby Versadial, New York, N.Y., a company under the Sea Change Group)(www.versadialworld.com)), or a multichamber mixer/dispenser that iscombined with a décor product applicator (for example, a brush, a spraybottle, or other applicator). Further, premixed ready-to-use bottlesand/or spray cans may be used to distribute and apply the décor product.

Additional technologies contemplated for application and/or dispersionof the décor product include multifunctional devices, such as, forexample, a device that combines packaging, design positioning, décorproduct application, and/or removal of a design device from a surface.For example, in one embodiment, a design device, for example, a stencilcontains the décor product, which can be released onto a surface byapplying a releasing agent, such as water, to the stencil. As anexample, the use of a dry décor product may be reversibly attached to astencil by means of a water-soluble adhesive or the décor product may beattached to a sticky side of a water-soluble transparent film. Furthertechnologies contemplated include sprayers that impart charges tocolorant droplets and/or stencils (similar to powder painting),sponging, and felt tip pens and liners.

The décor product in one embodiment may be applied using heat transfertechnology including, for example, that used by color copying machinessuch as a Xerox DOCUCOLOR™ 12 printing onto Xerox 3R5811 or anothersimilar transfer paper and/or similar combinations of materials providedby Hewlett Packard, Canon, Geo Knight & Co, Avery Dennison, and 3M.

Differing application factors are contemplated for encapsulated décorproduct particles including control release, temperature release,concentration release, and any other release mechanism known to thoseskilled in the art. For example, release of the contents of amicroencapsulated décor product particle contents may be triggered bychanges in pH, such as by applying a common solvent such as, forexample, an ammonia-containing solution. Examples of a temperaturerelease mechanism include exposure of the microencapsulated décorproduct particles to a temperature above a release threshold, where therelease of the microencapsulated décor product particle contents onlyoccurs above the predetermined threshold temperature. A concentrationrelease application may apply a portion of a colorant to the surfaceover an extended period of time to render a more evenly distributedand/or more thoroughly distributed appearance of the colorant to asurface. Illustratively, a microencapsulated décor product particle witha polymer resin particle shell and containing trapped colorant particlesand/or other compounds disclosed herein may be activated by thermalactivation and/or specific chemistry-related activation (including, forexample pH modulation using, for example, ammonia). As such, the outerpolymer shell would melt and/or dissolve, and the colorant particlesand/or other microparticle contents may be allowed to flow and thus beapplied to the surface. Nonexclusive examples of release mechanismsuseful in the present disclosure include those found in U.S. Pat. No.6,893,662. Additional release mechanisms contemplated for treating ofthe microencapsulated décor particle result in at least one of breaking,heating, weakening, and/or dissolving one or more shells of a décorparticle.

A décor product once applied and/or affixed to the surface may betemporary, permanent, and/or semi-permanent. An example of asemi-permanent décor product includes a décor product with a temporaryadhesive that adheres and/or attaches a décor particle to the surface.Such a formulation may provide short term durability, for example, hoursto weeks, of the décor product on a surface by substantially adheringand/or attaching the décor product thereon. In one embodiment, shortterm durability allows the décor product to be applied to a surface foran occasion, special event, and/or holiday without the décor productneeding to be affixed to the surface and at the same time being easilyremovable therefrom. An example of décor product attachment to a surfaceis seen in FIG. 2, which is a scanning electron micrograph showing drydécor particles 32 attached to an individual nylon carpet fiber 34.

Removal of the décor product from the surface may be either through dryremoval methods or wet removal methods such as through using variousdevices and methods including, for example, a vacuum, a vacuum combinedwith mechanical action such as agitation, wet extraction, steamcleaning, chemical application (for example, applying an organic orinorganic solvent), using an ultrasound process, using detergents, usingdilute ammonia solutions, and/or using an abrasive eraser. Some or allof the aforementioned processes may be employed to remove the décorproduct prior to and/or after setting, affixing, and/or curing of thedécor product on or to the surface.

Examples of solvents useful in the present disclosure include polarand/or nonpolar solvents, including those disclosed in the Handbook ofOrganic Solvent Properties, Smallwood, L M. 1996, Elsevier. Suchsolvents include, for example, water, hydrocarbons, aromatichydrocarbons, aliphatic hydrocarbon solvents such as aliphatic alcohols,other alcohols, glycol ethers, nitrated and chlorinated solvents such aschlorinated hydrocarbons, ketones, ethers, and/or esters. Other usefulsolvents include acetone, amines, benzyl acetate, phenols, polyvinylalcohol, and/or the organic sulfone or sulfoxide families includingdimethyl sulfoxide. Detergents and soaps may also be used to remove adécor product from the surface. Combinations of the above may also beused.

By way of example, reversibility of a décor product applied to a surfacemay be determined in the following manner. Initially, a test surface,such as, for example, a two-foot by two-foot square piece of nylonand/or polyester carpet is thoroughly cleaned using an upright vacuumcleaner (for example, a Bissell CLEANVIEW® II vacuum cleaner,manufactured by Bissell Homecare, Inc.) to remove loose fibers and/ordirt. The baseline color of each of three spots over which the décorproduct is applied is determined using a colorimeter such as a Minoltadata processor model DP-301 combined with a Minolta model CR-310 chromameter (both manufactured by Konica Minolta Sensing Americas, Inc.) setto the “L-a-b” setting to allow determination of ΔE (color change) andcalibrated according to the manufacturer's instructions.

The décor product is applied using, for example, a finger pump (output60 micron particle size) onto the surface of the three spots until thetest area is completely saturated. The décor product is allowed tosubstantially dry to the touch, which is typically overnight to assurecomplete drying, though shorter or longer periods may be used dependingon, for example, the relative humidity and/or temperature of the ambientenvironment. After the décor product is dry, the color of each of thethree spots is determined using the colorimeter as mentioned above.Subsequently, the three spots are vacuumed using a wet/dry vacuum with ahose attachment and brushless triangular tool, such as, for example, aShop-Vac® 1×1 portable wet/dry vacuum 12 V 60 Hz, 5.5 A, model 2101 A(manufactured by Shop-Vac, Inc.). The three spots are vacuumed in onedirection several times and repeated in the other direction for a periodof to ensure adequate removal. After vacuuming, a colorimetermeasurement is taken to determine the change in color. Change in color(Δ E) was determined using the following formula:

ΔE=√((L ₁ −L ₂)²+(a ₁ −a ₂)²+(b ₁ −b ₂)²)

where “L” refers to “lightness” with values of 0=black to 100=white;increasing “a” values indicate more red color and decreasing “a” valuesindicate more green color; and increasing “b” values indicate moreyellow color and decreasing “b” values indicate more blue color.

Illustratively, a substantially removable décor product has a ΔE valueas compared to the initial reading of an untreated carpet of less thanabout 20, or less than about 10, or less than about 7.5, or in the rangeof about 0 to about 15.

Factors that may affect reversibility of the décor product from asurface may include, for example, décor product specific factors,application specific factors, and/or surface specific factors. Examplesof décor product specific factors may include the type and/orconcentration of emulsifier included in the décor product formulation,which may affect adherent interactions between the décor product and thesurface to which the décor product is applied thereto. Further, when thedécor product composition includes a particulate component, for example,a décor particle, the reversibility of the décor product may be affectedby the size of the particle. Although not wishing to be bound by theory,it is believed that smaller particle size may affect reversibility dueto possible greater penetration of the particles into recesses andinterstices of a non-smooth surface such as carpet, thus reducing accessto the smaller particles for the subsequent removal process.

Application specific factors that may affect reversibility include theextent of surface saturation when applying the décor product to thesurface and the method and/or device used to apply the décor product tothe surface. Surface saturation includes, for example, the density ofapplied décor product on the surface. Greater surface saturation maylead to an increased likelihood of residual décor product remainingafter removing the major portion of décor product applied to thesurface, and/or greater penetration of the décor product into therecesses and interstices of the surface thereby reducing accessibilityof the removal process to the décor products. Further, the method and/orapplication device used to apply the décor product may affectreversibility. Illustratively, the décor product may be applied to asurface in a fashion to coat the surface with little to no surfacepenetration. For example, an applicator that applies the décor productin a mist, such as by a finger pump with a 60 micron or less spraynozzle, may be used to coat the surface with little or no penetration ofthe interstices of the surface. In this example, décor productreversibility may be improved owing to the minimal surface penetrationof the décor product. However, if it is desired to apply the décorproduct with an aerosol spray container, or other such applicator thatexpels the décor product from the container with a greater velocitythan, for example, a hand pump, deeper penetration of the surface mayresult, which may affect removal of the décor product from the surfaceby, for example, limiting or inhibiting access of the removal process tothe décor product.

Surface specific factors that may influence décor product reversibilityinclude, for example, surface structure and/or texture, theelectrostatic charge held by the surface, and/or surface pretreatmentsaffecting, for example, surface tension. Surface structure factors suchas fiber density, in the case of carpets and the like, may influencedécor product reversibility. For example, dense carpet structures may bemore likely to minimize particle penetration as opposed to openstructures such as, for example, nylon shag carpets and older carpetswith damaged braids. Thus, less dense surfaces may influence décorproduct reversibility by, for example, reducing the access of the décorproduct to the removal process as compared to more dense surfaces.

Further, surface electrostatic charge and/or surface tension mayinfluence reversibility. Illustratively, a surface treatment may be usedto lower the electrostatic charge and/or surface tension to improve thereversibility characteristics of the décor products. Examples of surfacetreatments that may be used include 3M SCOTCHGUARD™ Carpet andUpholstery Protector (manufactured by 3M) and/or Advanced TEFLON® Carpetprotector (manufactured by E. I. du Pont de Nemours and Company).Further, such pretreatments may promote décor product coverage and/ordispersion on the surface with smaller volumes of the décor product thusindirectly promoting décor product reversibility through minimizing therisk of oversaturation.

In some instances, the décor product may be formulated to have a largerparticle size to improve or enhance reversibility by reducing the amountof particles based on size that can penetrate the smaller interstices ofthe surface. Further, and not wishing to be bound by theory, it isbelieved that smaller sized particles, for example, particles less thanabout 5 to about 10 microns in size, may be held relatively more tightlyto the surface by an electrostatic charge and/or surface tension ascompared to larger particles, for example, particles greater than about20 microns in size, making the smaller sized particles relatively moredifficult to remove from the surface as compared to larger sizedparticles. Thus, in some embodiments, surface pretreatment, additionaleffort and/or additional methods may be needed to achieve the samereversibility characteristics for décor products formulated with smallerparticles as compared to décor products formulated with largerparticles.

Once a décor product of the present disclosure has been applied to asurface and the user has decided to keep the décor product on thesurface, the décor product may be cured and/or affixed by chemicalcuring and/or mechanical bonding to the surface temporarily,permanently, and/or semi-permanently according to the formulation of thedécor product. Any curing or affixing technique compatible with thedécor product and the surface is contemplated in the methods disclosedherein including, for example, the application of energy and/or achemical to the décor product. Examples of curing or affixing techniquesinclude, for example, heat curing, steam curing, pressure curing,exposure to an electromagnetic field, including for example, ultravioletradiation, radio frequency curing, a magnetic field, and the like,ultrasound curing, induction heat curing, solar heat curing, exothermicreaction heat curing, convective heat curing, and/or radiant heatcuring. Further, curing or affixation of the décor product may beaccomplished by exposure of the décor product to the ambientenvironment.

The décor product in one embodiment may be affixed to a surface usingheat in a range from about −7° C. to about 650° C., or about 4° C. toabout 400° C., or at a temperature less than about 260° C., or about 20°C. to about 180° C., or about 65° C. to about 120° C., or higher andlower temperatures depending on the surface in which the décor productis applied. Further, the duration of the curing or affixing step isgenerally décor product- and/or surface-specific, and illustratively,ranges from less than 1 second to about 15 minutes, or from about 15minutes to about 1 hour, or from about 1 hour to about 4 hours, or fromabout 5 hours to about 8 hours, or from about 8 to about 12 hours, orlonger for curing of the décor product.

Tools that may be used to cure and/or affix the décor product to asurface include, for example, a hot iron, an enclosure or framecontaining a CALROD™ heating element suspended over the surface beingheated, an enclosure or frame with one or more incandescent light bulbs,a heat gun, an enclosure or frame with a heater and a blower to infusehot air onto the substrate, an enclosure or frame with an infraredheating element, an enclosure or frame with an ultraviolet light source,a steam-making device, a heated tool (for example, a household iron, anelectric griddle, or a hair dryer or objects similar in function butspecifically designed for the application), or a microwave emittingdevice or a radio frequency emitting device. The devices contemplatedherein to be used for décor product affixation may incorporate heatsensors and timers to facilitate the affixation process and furtherprotect the surface to which the décor product is being applied fromdamage from overheating.

Additional ways to affix the décor product to a surface includeinductive heating of a décor product containing metal nano- ormicroparticles, moisture curing systems, adding magnetic enhancements toa deposited décor product, and treatment of additives within the décorproduct to induce affixation. Further ways to affix the décor product toa surface include those disclosed in the U.S. patent and publishedpatent application provided in Table No. 1 above.

An illustration of affixation is shown in FIG. 3. Here, the décorproduct has been applied to a surface 44, such as a nylon carpetdescribed herein and has substantially dried to the surface to formsubstantially dry décor particles 42 attached thereto. An affixationdevice 46 emitting energy 48, for example, an electromagnetic field, isbeing passed over the applied décor particles 42 in a direction A. Uponcontact of the emitted energy 48, the décor particles begin to melt andflow and upon removal of the emitted energy begin to cool and bond tothe surface 44 to become substantially affixed to the surface. A furtherexample of fixation is seen in FIG. 4, which is a scanning electronmicrograph showing a resultant décor particle film formed on individualfibers of a carpet.

Protective coverings may also be applied to a deposited décor productfor the purpose of affixing the décor product and/or to add to theresiliency of the décor product to wear. Useful protective coveringsinclude, for example, nanoparticle coating compositions disclosed in,for example, U.S. Pat. No. 6,872,444. Further, fixatives useful in thepresent disclosure include those used in artistry to fix and/or seal,for example, pastels, pencil, charcoal, crayon, ink, gouache, orwatercolor. Such fixatives include those available under the trade namesBlue Label Reworkable FIXATIF® (Martin F. Webber Co.), GOLDEN® ArchivalSpray Varnish (Golden Artist Colors Inc.), KRYLON® Workable Fixative(Krylon Products Group, The Sherwin-Williams Company), and LASCAUX® FineArt Fixative (Lascaux Colours & Restauro, Switzerland).

It is further contemplated that the surface to which a décor product isto be applied and/or affixed thereto may be conditioned prior to theapplication of the décor product. Examples of such conditioning include,but are not limited to cleaning, vacuuming, steam cleaning, bleaching,pH balancing, reducing the pH, increasing the pH, sweeping, painting,scrubbing, wetting, texturing, leveling, tilting, drying, heating,cooling, sanding, buffing, coating, removing coatings therefrom,reducing the electrostatic charge of the surface, and/or applying asurface treatment, such as an upholstery and carpet protector including,for example, 3M SCOTCHGAURD™ Carpet and Upholstery Protector(manufactured by 3M) and/or Advanced TEFLON® Carpet protector(manufactured by E. I. du Pont de Nemours and Company).

Illustratively, the durability of a substantially affixed décor productcan be expressed in terms of a ΔE value by determining the ratio of theΔE measured between an untreated surface and a décor product affixed onthe surface and the ΔE measured between the untreated surface and thedécor product affixed and subsequently vacuumed as described herein andsubtracting this ratio from 100. Illustratively, the percentage changein ΔE for a substantially affixed décor product has a range of about 0%to about 20% change in ΔE.

A further embodiment of the present disclosure includes the use of adesign device that a user may use to control the application of thedécor product to a surface for the purpose of creating, for example, apattern on the surface to enhance the aesthetic effect of the décorproduct. Possible décor product patterns on surfaces contemplated in thepresent disclosure include any and all images, patterns, shapes, and/ordesigns. Preselected or random patterns may also be imparted to asurface using an inherent dispersal pattern from a décor productapplicator with or without movement of the applicator over a selectedsurface during application of the décor product. For example, by using aspray applicator with a cone-shaped dispersal pattern, a user may chooseto apply discrete spots and/or circles having diameters that are variedby varying the distance from which the applicator is held from thesurface during application of the décor product. Further, a user maymove the applicator during application of the décor product over thesurface in a predetermined or random pattern to achieve a predeterminedor random pattern on the surface. As such, preselected patterns and/orrandom patterns may be imparted to a surface with or without a designdevice.

Design devices contemplated in the present disclosure may limit, direct,focus, concentrate, guide, dilute, and/or disperse an amount of décorproduct applied to certain predetermined areas of a selected surface.The design device may include, for example, a stencil, a template, anarray, a guide, a frame, a pattern imparting device, a device impartinggraphics in a random manner, a manual device, an automatic device, acomputer guided device, a programmed device, and/or any combinationthereof. The design device contemplated for use herein including, forexample, a stencil, may be constructed totally or in part with amaterial such as, for example, paper, wood, stone, plastic, cardboard,metal, and/or any combination thereof.

Stencils or other design devices contemplated for use in the presentdisclosure may be designed, constructed, shaped, and/or reshaped, in apredetermined, ordered, disorganized, and/or random manner by means oflaser, knife, die cutting, and/or any other appropriate means asdetermined by the nature of the stencil material (for example, hardnessor softness of the stencil materials) to render a predetermined,ordered, disorganized, and/or random shape that allows a predetermined,ordered, disorganized, and/or random deposition of at least a visualdesign by introducing a décor product on a surface. The stencils mayfurther be laminated and have additional layers applied theretopost-construction and/or post-designing.

An exemplary stencil 60 useful in the present disclosure is shown inFIG. 5 and includes a material containment layer 62 (for example, forthe absorption of liquids and/or entrapping of dry materials and/orsolids) that includes a paper tissue, a synthetic woven or non-wovenmaterial that may or may not be coated with an absorbent hydrophilicmaterial, and/or a solid and/or liquid entrapping substance. Thematerial containment layer may have a thickness of about 0.01 mil toabout 1000 mils, or about 0.1 mil to about 500 mils, or about 0.5 mil toabout 150 mils, or about 1.25 mils to about 50 mils, or about 2 mils toabout 15 mils, or a lesser or greater thicknesses depending on theapplication. The stencil may also incorporate a liquid barrier layer 64to protect a selected surface from unintended colorant exposure that maycomprise a liquid barrier made of any hydrophobic material, including apolyolefin such as polyethylene. The liquid barrier layer 64 may also becomprised of a coating applied to one surface of the absorbent materialto hinder liquid transport through the absorbent material. Such acoating may be polymeric in composition such as an acrylic polymer. Theliquid barrier may have a thickness in the range of about 0.01 to about1000 mils, or about 0.1 mil to about 500 mils, or about 0.5 mil to about150 mils, or about 1.25 mils to about 50 mils, or about 2 mils to about15 mils, or lesser or greater thicknesses depending on the application.An example of a material containment layer and barrier layer combinedtogether useful in the present disclosure, includes the commerciallyavailable GOTCHA COVERED® drop cloth by Kimberly-Clark Corp. The stencil60 further includes a first support layer 66 that helps to secure theedges of one or more cutout portions 68 that provides a passage throughat least the material containment layer 62 and the liquid barrier layer64 of the stencil 60. In this embodiment, the first support layer 66comprises threads, but other materials may be used, in addition to or inplace of threads as described below. Further, the stencil 60 includes asecond support layer 70 that helps to secure the stencil 60 to a surface(not shown), such as a carpet. The second support layer 70 may consistof adherent materials including, for example, adherent mesh-likematerials as described below.

A cross-sectional view of the stencil 60 is shown in FIG. 6. Here, thecutout portions 68 are shown through the material containment layer 62,the liquid barrier layer 64, and the second support layer 70. However,the second support layer 70 need not have the cutout portion 68 passtherethrough to allow a décor product to be deposited on a surface dueto its mesh-like structure.

In another embodiment, the material containment layer and the barrierlayer may be made of the same material. For example, a dual purposematerial (for example, a paper material) that has densities that differby layers. In this example, the top layer of the dual purpose materialcorresponds to the material containment layer and has a density thatabsorbs liquids and/or entraps dry material and/or solids and the bottomlayer corresponds to the barrier layer and has a density that preventspassage of liquids therethrough. Further, varying thicknesses maycontribute to the functionality of the dual purpose material previouslydescribed in addition to or in lieu of varying material densities. Sucha dual purpose material may be advantageous over using multiplematerials to create a stencil envisioned in the current disclosure byfacilitating manufacture of the stencil.

Another stencil that may be used in the present disclosure may alsoinclude a fibrous support layer that has securement and/or attachmentproperties, such as tulle, scrim, VELCRO®, VERSA HOOK from AveryDennison, and the like. Illustratively, when the support layer is laidupon a surface, the support layer comes in contact with the surface towhich the stencil is to be releasably secured in such a way as toadequately secure the stencil to the surface to allow deposition of thedécor product upon the surface and render the intended result. Thesupport layer may also comprise other adherent mechanisms, properties,and/or devices such as, adhesive strips, pressure-sensitive adhesive,and/or any standard bonding mechanism known to those skilled in the art.An additional support layer including, for example, a loose grid, web,or mesh-like material including, for example, thread, is envisioned thatmay be placed adjacent the barrier layer of the stencil. In thisembodiment, the cutout portion may extend through the materialcontainment layer, the barrier layer, and the support layer. Anexemplary stencil useful in the present disclosure in which the supportlayer is a pressure-sensitive adhesive includes that disclosed in, forexample, U.S. Pat. No. 6,779,443. The support layer may be of sufficientarea to minimize unintended exposure of a surface, as well as functionto maintain the structural integrity of the stencil.

Stencils that may be used in this application may be substantiallyresilient to décor product removing means and/or affixation means. Thestencil may be used to protect underlying surfaces from the décorproduct removing means disclosed herein. Further, stencils contemplatedwithin the context of the present disclosure when disposed upon asurface may protect portions of the selected surface from at least oneof application, removal, or affixation of the décor product by means ofat least one of the material containment layer or the barrier layer.Further, a design device may protect an area adjacent to the preselectedpattern from receipt of the décor product.

Stencils contemplated in the present disclosure may have cutout portionsand/or peripheral edges substantially shaped into a desired pattern,shape, and/or design. Illustratively, as seen in FIG. 7, a stencil 80has star-shaped peripheral edge 82 and an internal cutout 84 having asimilar shape as the peripheral edge. This exemplary stencil may beused, for example, when a décor product is being applied to a large areaof a surface such that the stencil base 86 between the peripheral edge82 and the internal cutout 84 blocks application of the décor product tothe surface to leave a décor product-free pattern on the surface.

The stencil may also have one or more cut-out portions and/or pre-cutpunch-out portions that may be selectively removed by a user. Reverseimage stencils contemplated in one embodiment may be used to impart areverse visual image upon a surface by first being placed upon thesurface to which a décor product is intended to be applied. In thisembodiment, the peripheral edge of the stencil is cut and/or constructedto impart a pattern, shape, and/or design to a surface when a décorproduct is applied to the stencil and underlying surface. It isenvisioned, that the reverse image stencil may or may not have a cutoutportion therethrough. After the placing of the stencil or stencils, thedécor product is applied to both the surface and the stencils. Thestencil or stencils function to protect the underlying surface in theshape of the desired image resulting in a décor product-free area in theshape of the desired image surrounded by a décor product covered areaoutlining the desired shape. Further, conventional stencils contemplatedin the present disclosure may be used to impart a visual image upon anintended surface by first being placed upon the surface to which a décorproduct is intended to be applied, after the placing of the stencil orstencils the décor product is applied to both the surface and thestencils, and the stencil or stencils function to protect the surfacesurrounding the shape of the desired image resulting in a décor productcovered area in the shape of the desired image surrounded by a décorproduct-free area outlining the desired shape.

Another illustrative stencil imparts an image to a surface when used inconjunction with the décor product removal means, such as, for example,a vacuum, after the décor product has been applied to the surface. Inthis example, the décor product is first applied to the surface and thestencil is placed on the surface where the décor product had beenapplied. After the stencil has been applied to the treated area, a usermay apply a second décor product to the treated area and stencil toimpart multiple patterns of different décor products a surface. Thisprocess may be repeated until a desired affect is achieved.Alternatively, after applying the stencil to the treated area, the décorproduct that remains exposed within cutout portions of the stenciland/or in areas surrounding the peripheral edges of the stencil may beremoved by décor product removing means disclosed herein. The removal ofthe décor product results in images similar to those with the reverseimage stencils and/or the conventional stencils disclosed above.

One or more stencils may be used simultaneously to apply a visual designto a surface. When desired, one or more stencils may be used incombination with any number of other stencils contemplated in thepresent disclosure and/or auxiliary devices that aid in design formationand/or stencil communication. A multiplicity of stencils intended to beused together to impart a design or other graphic representation on aselected surface may be coordinated with relation to one another and theroom or volume of choice by coordinating, aligning, interfacing,connecting, and/or guiding systems that secure the stencils eithertogether or apart from each other or from predetermined or randompositions within a room or other volume either on the surface on whichthe décor is intended to be applied or any other point in the room orother volume. Examples of coordinating, aligning, interfacing,connecting, and/or guiding means useful herein include reusable ordisposable pegs that anchor stencils and/or additional auxiliary devicesthat aid in design formation and/or stencil communication together viapeg securement locations, color strips disposed along a surface of thestencils, letters, symbols, notches, and/or other indicia that guideassembly of the stencil organization. An example of a stencilcoordinating mechanism is illustrated in FIGS. 8-11.

FIG. 8 depicts a disposable and/or reusable peg 90 that can be affixedto a surface to form an anchor point on the surface for coordinatingstencil placement on the surface. In this example, the peg 90 hasmultiple layers of adhesive strips 92 to adhere the peg to the surface,however, a single strip may be included or some other adherent mechanismsuch as VELCRO® dots and/or other adhesive agents known to those skilledin the art.

FIG. 9 shows a transparent layout tool 102 that may be placed on asurface 104 to be decorated. The layout tool 102 includes one or morespacing portions 106, for example, an array, sized to permit one or morepegs 90 to be inserted (as shown by arrow B) into the spacing portionand attached to the surface 104. The layout tool may also include acolored pattern that may serve as a preview for a selected décor designthat may be achieved using a corresponding set of stencils. To determineplacement of the layout tool 102 on the surface 104 in order to, forexample, center the layout tool on the surface, the user may measure adistance from a feature on the surface, for example, a floor vent, ormay measure a distance from a wall or other room feature to determinedesired placement of the layout tool.

By using of a plurality of pegs 90 along with the layout tool 102, auser may construct an array 112 of pegs attached to the surface 104 asis seen in FIG. 10. To coordinate one or more stencils on the surface104 using the coordinating mechanism of the current embodiment, the usermay place a stencil 122 or a layout tool having a hollow peg 124centered over a hole in the stencil (not shown) on top of one of thepegs 90 adhered to the surface 104 (as shown by arrow C) to anchor thestencil on the surface. Alternatively, the hole in the stencil 122 mayserve to receive the peg 90 and orient the stencil on the surface. It isalso envisioned that a stencil 122 may include more than one hole and/orhollow peg 124, for example, a hollow peg at each corner of a squarestencil, to securely position the stencil on the surface. Further, in asimilar fashion, additional layout tools 102 that include holes and/orhollow pegs 124 may be positioned on the surface 104 in a predictableand symmetrical manner by starting with a minimal number of measurementsfor the first layout tool position. In this way, an array of pegs 90 maybe placed on a large surface using one layout tool 102 to allow a largenumber of stencils to be placed on the surface 104 to permit an entiresurface to be decorated with at one time.

Use of coordinating, interfacing, and/or guiding means may allow theconsumer to impart a décor product in predetermined or random patterns,designs, images, lines, geometric shapes, discrete images, and/orrepetitive images and the like, in a visually perceived organized manneror a visually perceived disorganized and/or random manner.

Any and all images, patterns, shapes, and/or designs may be imparted ona surface using the design devices of the present disclosure. Forexample, images, patterns, shapes, and/or designs contemplated in thepresent disclosure may be regular or non-regular, linear or non-linear,and repeatable or non-repeatable patterns, including, for example,ornamental, tracery, or geometric forms, simplified primitive andsymbolic images and patterns, compositional multi-object landscapes,images depicting real or imaginary stories or plots, images with text,art images, standard and/or reproducible images, real or imaginaryletters, real or imaginary numbers, cartoons, real or imaginarytypographical symbols, illustrations, patterns, designs, indicia, and/orshapes, and combinations thereof.

Further, images, patterns, shapes, and/or designs useful in the presentdisclosure may be varied by palette, combination of standard or randomimages, size, positioning on a surface and/or customized by combinationof multiple parameters, for example, pictures, patterns, palette, size,positioning, among others. The images, patterns, shapes, and/or designsuseful in the present disclosure may also be varied by coloring withreflective and/or refractive elements, optical effects provided by anovercoat, the use of optical properties of static or dynamic flatimages, and/or use of tactile properties imparted to a surface byadditives and/or by affixation of the décor product.

It is further contemplated that images, patterns, shapes, and/or designsuseful in the present disclosure may also be chosen by the consumerbased on like or dislike, visual evaluation by comparing an image with astandard set of images, colors, and/or templates. The images, patterns,shapes, and/or designs useful in the present disclosure may also bechosen based on an interactive digital library with changeableparameters for adjustment to specific room or other volume environments,and may also be based on computer modeling for a specific room or othervolume.

Further still, the images, patterns, shapes, and/or designs contemplatedmay be, for example, the result of freestyle design, the creation ofsingle color images using varied forms of stencils, the creation ofmultiple color images using several stencils, the creation of multiplecolor images using compound stencils where with a sequential andpossibly repeated manner one color is applied to a surface and stencil,then a layer of stencil removed and a protective layer added to protectthe first color and/or a second color is immediately applied creating acolor mixture on the dual exposed areas and a single color area on thesingle exposure areas, transfer of prefabricated images from a carrier,and/or sequential image fabrication from standard elements such aslines, dots, and/or pixels.

Additional images, patterns, shapes, and/or designs contemplated may beunique art work, single independent images, one or more systems ofconnected, potentially interrelated images coordinated with theimmediate environment (with a room or objects within or characteristicof a room), and/or a two way coordination of decorative images on one ormore surfaces and immediate surroundings. Further, images, patterns,shapes, and/or designs contemplated may serve purposes beyond visualornamentation, such as teaching, directing, and/or instructing,including prompts, reminders, messages, alphabets, maps, equations,phrases, poems, warnings, language tools, or indexing means (forexample, bar codes).

It is also contemplated that combining one or more décor products withat least one stencil allows a user to create images that may bemonochromatic with constant or varied intensity and with or withoutshadow effects. Further, images possible using the present disclosuremay also be polychromatic with constant or varied intensity and with orwithout shadow effects, or may be two or more color contrast imagesachieved via multiple patches of colors and shapes. Polychromatic imagesmay have mixed or intermediate colors and may or may not providecomplete and natural palette. Any number of variations to the appearanceof a treated surface may be achieved using the compositions of the décorproduct envisioned in this disclosure along with or more design devices.

An example of using the décor product with a design device is describedhereafter. As seen in FIG. 12, a method of applying a design to a softsurface such as a carpet is shown generally at 200. In one embodiment,the carpet is already been installed in a room and may be substantiallydry, although the method may be undertaken on a wet or humid surface aswell. To apply the design to the carpet, according to one method of thepresent disclosure, a user first selects one or more design devices atstep 212.

In addition to selecting one or more design devices, a user may selectone or more décor products to be incorporated into the design that maydiffer, for example, by color. One or more consumer aids may be used toassist the user in making these selections. The design mechanisms mayinclude, for example, a user making a simple decorating decision, suchas determining an arrangement of design devices and colors tosophisticated computer design aids, such as CD-ROM training programsthat teach color application or provide creative suggestions. Additionalconsumer aid design mechanisms include color analysis, matching, andblending, and may include the use of colorimeters, color scanners,and/or software algorithms. Further examples of consumer aids, aredisclosed herein.

Once the user has selected one or more design devices, the user thenplaces the design device adjacent the carpet (step 214). The one or moredesign devices may be placed in any arrangement on the carpet and maycover a small portion of the surface, such as a center, edge, or corner,or substantially the entire carpet, or any amount therebetween.

After the one or more design devices have been placed in a desiredarrangement on the carpet, the user applies a décor product to a cutoutportion of the design device at step 216. Alternatively, or in additionto, the décor product may be placed on portions of the design devicethat directly contact (for example, a non-cutout portion of the designdevice) the soft surface. Upon contacting the surface, the user mayallow the décor product to substantially dry on the surface at step 218.After application of the décor product the design device may be left inplace while the décor product dries or may be removed from the surfaceimmediately after application at step 220. If the used decides not tokeep the design on the surface, the user may substantially remove thedécor product from the surface as described herein at step 222.Otherwise, if the user decides to keep the design, the user maysubstantially affix the décor product to the surface as described hereinat step 224. Further, the design device may be removed from the surfacebefore or after the décor product is removed from or affixed to thesurface.

An example of a stencil 230 useful in the present disclosure is shown inFIG. 13. The stencil 230 consists of a stencil base 232 and a cutoutportion 234. The stencil base 232, including the material containmentlayer (not shown), barrier layer (not shown), and a support layer 236,is made out of any appropriate material including, for example, paper,plastic, cardboard, cloth, synthetic fabric, natural fabric, cellulose,and/or metal, or any other desired material. The cutout portion 234consists of any pattern, shape, or design desired. A support layer 236,as is visible through the cutout portion 234, is provided adjacent abottom surface of the stencil base 232. The stencil 230 is used tocreate an image on a surface by applying the décor product to the cutoutportion 234 of the stencil, wherein upon removal of the stencil, thedesign is left on the surface of the carpet. The décor product can thenbe removed or affixed.

A bottom view of the stencil 230 is shown in FIG. 13A, further depictingthe support layer 236. The support layer 236 extends across a smallportion of a bottom surface of the stencil base 232, but may extend toand/or beyond edges of the stencil base. The support layer 236 assistsin securing the stencil 230 to a soft surface, securing the edges of thestencil, keeping the stencil flat, and securing and/or facilitating thetransfer of a décor product.

A cross section of a stencil useful in the present disclosure andsimilar to the stencil 230 of FIGS. 13 and 13A is shown at 240 in FIG.14. The stencil 240 includes an absorbent top layer 242, a liquidbarrier layer 244, and cutout portions 246 representing a cutout portionof a design, such as the cutout portion 234 (FIGS. 13 and 13A). Inaddition, the stencil 240 may be disposed adjacent a carpet 248. Theabsorbent top layer 242 inhibits or prevents dripping and/or bleeding ofa décor product while on the carpet 248, as well as when the stencil 240is removed from the carpet, and may consist of, for example, papertissue and/or a synthetic non-woven material coated with an absorbent,hydrophilic material. The liquid barrier layer 244 is disposed adjacentthe absorbent top layer 242 and inhibits or prevents the décor productfrom seeping through to the carpet 248 and may consist of anyhydrophobic material, including, for example, a polyolefin such aspolyethylene.

A cross sectional view of the stencil 230 is shown in FIG. 15. Thestencil 230 includes an absorbent top layer 252, a liquid barrier layer254, and cutout portions 234, and may be disposed adjacent a carpet 259.The stencil 250 further includes a support layer 236 that may consist ofa woven and/or non-woven mesh material, such as, for example, tulle,scrim, and/or cheesecloth spanning the cutout portion and that allowsthe décor product to substantially pass therethrough.

FIG. 16 illustrates an additional stencil that may be provided, forexample, in a kit, shown generally at 270. The stencil 270 may be usedat a border of a carpet and includes a stencil base 272 and a cutoutportion 274. The stencil 270 also includes color strips 276 and 278having a specific color thereon, for the purpose of aligning the stencil270 with one or more additional stencils having corresponding and/orcomplementary color strips.

A stencil 280 that may be used at a corner of a carpet is shown in FIG.17. The stencil 280 includes a stencil base 282 and a cutout portion284. The stencil 280 further includes color strips 286 and 288 and anarrow 290 used for aligning the stencil 280 with internal surfaces of acorner of the carpet.

Two additional stencils are shown in FIG. 18 and FIG. 19. A stencil 1000of FIG. 18 may be used at a first end of a carpet and includes a stencilbase 1020, a cutout portion 1040, and a color strip 1060. A stencil 1100of FIG. 19 may be used at a second end of a carpet and includes astencil base 1120, a cutout portion 1140, and a color strip 1160.

FIGS. 20-22 illustrate an exemplary application of the respectivestencils 270, 280, 1000, 1100 of FIGS. 16-19 to a carpet 1260 accordingto a sample set of instructions that may be provided in a kit along withthe stencils. As shown in FIG. 20, a room 1200 is provided forillustrative purposes. The room 1200 includes a first wall 1220, asecond wall 1240, and the carpet 1260. Following the instructionsprovided, the user is instructed to place the corner stencil 280 of FIG.17 into a corner formed by walls 1220 and 1240, wherein the arrow 290 ispointing to the corner.

The user is further instructed to place first and second border stencils270 of FIG. 16, adjacent the corner stencil 280 of FIG. 17, as shown inFIG. 21. The color strip 276 of the first border stencil 270 is placedon top of or adjacent the color strip (not shown) of the corner stencil280 having the same color thereon. Likewise, the color strip 278 of thesecond border stencil 270 is placed on top of or adjacent the colorstrip (not shown) of the corner stencil 280 having the same colorthereon.

Further, and as shown in FIG. 22, the user is instructed to place thefirst and second end stencils 1000 and 1100 of FIGS. 18 and 19,respectively, adjacent the first and second border stencils 270. Thecolor strip 1060 of the first end stencil 1000 is placed on top of thecolor strip (not shown) of the first border stencil 270 having the samecolor thereon. Likewise, the color strip 1160 of the second end stencil1100 is placed on top of the color strip (not shown) of the secondborder stencil 270 having the same color thereon.

The user may then apply (for example, by spraying) the décor product onthe cutout portions of the stencils 270, 280, 1000, 1100. After applyingthe décor product, the user may remove the stencils to view the designproduced on the carpet by the remaining décor product 1520. A sampledesign created by the remaining décor product 1520 is shown generally at1500 in FIG. 23.

In yet an alternative embodiment, a room 1600 is shown in FIG. 24. Fourwalls 1620, 1640, 1660, and 1680 define outer portions of a carpet 1700.A design device, such as a grid pattern 1720, may be used in conjunctionwith one or more design devices, such as a stencil 1740. The gridpattern 1720 may be designed to cover all or a portion of the carpet1700. Once the grid pattern 1720 is placed adjacent the carpet 1700, oneor more stencils, such as the stencil 1740 having a cutout portion 1760therethrough, may be used to create a design. The stencil 1740 and thegrid pattern 1720 may include color strips, such as the color stripsillustrated in FIGS. 16-19 to assist the user in arranging the designdevices. Alternatively, letters, symbols, notches, indicia and/or otherunique identifiers may be used to assist in arrangement of the stencil1740 with the grid pattern 1720.

In addition to creating discrete images and the like as disclosed above,the present disclosure may be used as a resource for large area interiordesign in a commercial and/or non-commercial setting. In this capacity,the present disclosure may be used, for example, to create a border on asurface that would be monochromatic (solid, discrete design, randomdesign) or polychromatic (solid, discrete design, random design) or tocreate a whole room change such as discrete shapes, images, design,random shapes by applying a monochromatic solid or non-solid or apolychromatic solid or non-solid décor product (full coverage) from wallto wall or that would account for complex room peripheries, such asfireplace stoops, door/entryways, jogs in walls, carpet to non-carpetthresholds, sunken or raised portions in rooms, floor vents, outlets,other built in items disruptive of surfaces in general.

Still further, the present disclosure may be used for creating adiscrete image in a selected area of interest as determined by the usersuch as, for example, a wall, a ceiling, a doorway, an entryway, awalkway, a hallway, a stair, or a flight of stairs, or at the top of aflight of stairs, or in front of or over a hearth or fireplace.

The present disclosure also provides kits that contain one or morecomponents herein described, including, for example, a design deviceand/or a décor product that may be substantially removed from a surfaceprior to being affixed thereon. A set of instructions may also beincluded in the kit instructing the user how to apply the design to asoft surface such as a carpet. The kit may further comprise one or moreapplication devices for transferring the décor product to the carpetand/or one or more fixative devices for affixing the décor product tothe surface. In addition, the kit may include a protective covering forprotecting the décor product after it has been applied to the carpet,especially while it is drying. The kit may further include an ironscreen that is used to provide a user with an indication of what areasof the décor product have already been ironed or affixed.

As an example, the kit may be provided having one or more stencils, forexample, five stencils, a décor product, an application device such as asprayer, an affixing device such as a heating device (for example, aniron or a radio frequency emitting device), and/or a set ofinstructions. The kit may also include a system to identify, choose,make, modify, and/or prepare the surface on which the décor product isto be applied.

Numerous options for customization of the present disclosure may beutilized with the assistance of one or more consumer aids. Consumer aidscontemplated in the present disclosure, which may be provided in a kit,individually and/or in any suitable fashion, include any and all designmechanisms and/or aids and devices that enable the consumer to use thepresent disclosure including instructions, color predicting aids, designtemplates showing the look prior to and/or after decorating possiblyusing a software algorithm to present a retrospective view of a surfacetreated with the décor product, instructional videos, CD-ROMs, internetweb pages to select and predict designs, colors, and overall looks,interactive computers terminals, in store displays, customer service,advertising, training courses, recorded messages, text messages,mailings, books, literature, lectures, training courses, correspondencecourses, and any combination thereof, as well as, other communicatingmeans. Through the aforementioned communicating means, a user may betaught, for example, how to use a kit including the present disclosure.Further, the user may be instructed how to employ the disclosure forcommercial applications such as, for example, interior designapplications.

Additional consumer aids include devices to be employed by persons suchas a user, an agent of the user, a trainer, a displayer, a salesman, ateacher, or a technician to enable the user to use the presentdisclosure such as color carpet chips, for example, pieces of carpetwith differing décor product formulations of differing coverage affixedthereon to demonstrate how different décor product formulations appearon different types and/or colors of carpet. Further consumer aidsinclude color templates, for example, sheets of opaque or clear materialof different colors with different colors of décor product affixedthereon with instructional ratios of the base colorants used to makeeach décor product color to allow the user to make each décor productcolor from the separate base colorants and other additives.

Illustratively, in FIG. 25 an exemplary consumer aid 2000 is shown thatenables a user to preview how a pattern will appear in a certain color(or shade or tint or texture, and any other variation) on a surface whenthe consumer aid is placed on the surface. The consumer aid 2000 mayenable the user to make or mix the décor product and/or assist the userin selecting the color of the décor product that would be an appropriateand/or aesthetically pleasing color and/or contrast when compared to thebase color of the surface. The consumer aid 2000, in this case, isincluded in a kit having two décor products of differing colors, such asdark gray and white. Further, the consumer aid 2000 includesinstructions on how to achieve each variation in pattern displayed onthe consumer aid, in this case varying shades of gray. The consumer aid2000 of the current embodiment includes a transparent sheet 2002 uponwhich is disposed a pattern 2004 that is repeated a number of times,such as six times. Each repeat has a different shade of gray becomingmore white progressing from upper left to lower right, as is seen bycomparing, for example, pattern 2004 and pattern 2006. Beneath eachpattern repeat is a ratio printed on the transparent sheet 2002 thatindicates a mixture percentage, such as is seen at 2008 where a mixtureof 100 percent dark gray and 0 percent white is indicated or as is seenat 2010 where a mixture of 20 percent dark gray and 80 percent white isindicated. In this way, a user may achieve each of the shades of grayassociated with each pattern repeat by mixing the dark gray and whitedécor products included in the kit at the percentages indicated.Further, any color may be created in this manner by mixing appropriateamounts of differing colored décor products. Further, any sort ofinstructions is contemplated to instruct a user to achieve a given colorand/or pattern appearance. Further, the kit may also include a combinedmixing and application device that contains the décor product(s) andcorresponds with the consumer aid, such that the percentages given theexample above for mixing dark gray and white décor products may indicatehow to adjust the settings on the mixing and application device toachieve the indicated color or shade or texture shown on the consumeraid 2000.

Additional consumer aids include carpet templates, stencil templates,for example, templates illustrative of different images and imagecharacteristics that are possible or desirable to a user, as well as howdifferent stencils can be used together, positional templates, forexample, templates that indicate to a user how a décor product image canbe incorporated on a surface in a given space, tester samples (similarto the tester samples supplied by Benjamin Moore & Co.), trial periods,color matching sheets, for example, similar to color matching sheetsused in make-up matching to skin tones, used to match colors, or topredict color look and contrast, color blending sheets, for example,similar to color matching sheets that further allow a user to previewcombined colors on a surface, color charts, color graphs, color analysisdevices, colorimeters, color scanners, software algorithms for colorassessment and formulating colors, and other means for determiningproportions and types of décor product to be used for a specified orunspecified surface in a room, hallway, house, building, or other area.

In addition, by mixing differently colored décor products, any number ofadditional colors may be formed. As an example, a user may purchase oneor more pre-formulated décor products including colored toners and/orother décor particles or may mix various colored toners to achieve anydesired color. Design mechanisms such as color charts, color analysisdevices, or other ways for deter mining the proportion and type ofcolored toner to achieve a particular color can also be provided to auser. Additionally, a user may directly apply the toners to the surfaceor the toners may be incorporated into the décor product such as bymixing the toner with water or another solvent, or a predeterminedformulation of more than one part to make a liquid suspension oremulsion, for example, and then applied to the surface.

Additional consumer aids include devices to be employed by the user tohelp the user identify, (for example, tools and/or kits used to identifythe type or composition of carpet fibers to help direct the user towarda particular décor product formulation), choose, make, modify (forexample, kits or compounds that can be included in kits to alter thephysical appearance of a surface, such as an embossing compound),combine, and prepare surfaces on which a décor product may be appliedand/or affixed. These consumer aids enable the user to choose thecorrect décor product formulation for a given surface to have a givenintended effect, for example, a textured look on a soft surface or asmooth look on a hard surface, or any combination thereof.

Further, the consumer aids will help users in choosing, making,modifying, combining and/or preparing design devices, such as a stencil,to render images, patterns, shapes, and/or designs to be imparted to thesurface when applying the stencil and/or a décor product to the intendedsurface. Still further, the consumer aids contemplated help or assistthe user in choosing, using, making, modifying, and/or preparing décorproduct formulations that may be ready-to-use or require preparationprior to application to a surface.

In addition to selecting one or more design devices, a user may selectone or more colors to incorporate into the design. One or more designmechanisms may be used to assist the user in making these selections.The design mechanisms may include, for example, a user making a simpledecorating decision, such as determining an arrangement of designdevices and colors to sophisticated computer design aids, such as CD-ROMtraining programs that teach color application or provide creativesuggestions. Additional design mechanisms include color analysis,matching, and blending, and may include the use of colorimeters, colorscanners, and/or software algorithms.

Additional consumer aids may take the form of store displays and/orpresentations of the disclosure, including, for example, the décorproduct packaged in liquid form or powder form to be suspended in liquidimmediately before use, and/or one or multiple décor product colors anddécor product additives to be mixed before use, and/or a kit comprisingelements of the present disclosure such as multiple or single colors,one or more designs, instructions, an application device, a fixativedevice, a protective covering, and/or an iron screen or other indicator,such as, for example, a color changing additive, to differentiatebetween fixed and unfixed areas of the applied décor product.

Illustrative chemistries useful in a décor product composition includesa low temperature cure epoxy décor particle, a low temperature cureepoxy-polyester hybrid décor particle, and/or a low temperature curepolyester-triglycidyl isocyanurate (TGIC) décor particle. Typical rangesof constituents of the aforementioned décor particles contemplated inthe present disclosure include an amount of binder, which includes atleast a polymer or resin and one or more curatives, based on weightpercentages of about 50% or greater of the total weight of the décorparticle. Further, other components of the décor particle, including,for example, additives, fillers, pigments, degassing agents, flowadditives, and the like, may be included in amounts ranging from about50% or less of the total weight of the décor particle. Such ranges maybe adjusted to attain the desired characteristics of the décor particleas appropriate as is known to those skilled in the art. Further, toassure full stoichiometry of reactions between polymers and/or resinsand curatives, amounts of polymers and/or resins and curatives used mayrange from about 50% to about 150% based on relative equivalent weightsof the compounds and/or as recommended by the manufacturer.

A low temperature cure epoxy décor particle may include a binder systemthat has an epoxy resin and a curative. An example of an epoxy resin isa bisphenol A resin having the following general chemical structure ofFormula I:

wherein n is an integer from 2 to 20.

Bisphenol A epoxy resins useful in a décor particle include those resinshaving an epoxy equivalent weight of about 650 to about 900, or about700 to about 750; a Tg of about 45° C. to about 75° C., or about 55° C.;and/or an ICI cone and plate viscosity of about 5 poise to about 100poise, or about 35 poise at 150° C.

Another example of an epoxy resin useful in a décor product formulationis a novolac epoxy resin. Examples of novolac epoxy resins include thefollowing general chemical structures of Formulas II and III:

wherein n is an integer from 1 to 4.

The glass transition temperatures and viscosities of the novolac epoxyresins are similar to those provided above for the bisphenol A epoxyresins. A curative agent useful in a binder system that has an epoxyresin includes, for example, a phenolic curative. An example of aphenolic curative agent is Huntsman Hardener XB 3086 supplied byHuntsman Advanced Materials (Switzerland) GmbH, which is compatible withbisphenol-A-based epoxy resins and novolac-epoxy-based resins. TheHuntsman Hardener XB 3086 contains phenol,4,4′-(1-methylethylidene)bis-, polymer with2,2′-[(1-methylethylidene)bis(4,1-phenyleneoxymethylene)]bis[oxirane](commonly described as a polymer of epoxy resin and bisphenol A), aHuntsman Advanced Materials confidential accelerator, and Phenol,4,4′-(1-methylethylidene)bis- (commonly known as Bisphenol A). TheHuntsman Hardener XB 3086 has the following properties: amine value of0.83-0.93 eq/kg, recommended combining weight of about 135, and asoftening point of 84° C. to 94° C.

Stoichiometric ratios of the epoxy resin and the curative are calculatedbased on the combining weights, or equivalent values, of resins andcuratives. Values of the combining weights may be determined by chemicalstructure (for example, average molecular weight divided by the numberof reactive groups, amine values, acid or hydroxyl numbers, etc.) orempirically based on laboratory experiments. For example, using a lowermolecular type 3 bisphenol A epoxy resin with an epoxy equivalent weight(EEW) of 700 and Huntsman Hardener XB 3086 with a manufacturerrecommended equivalent weight of 135, the calculation for a full (100%)stoichiometry is shown below in Table No. 2.

TABLE NO. 2 Full Stoichiometry of an Epoxy Resin and Curative AgentDécor Particle. Epoxy Equivalent Approx. Constituent Weight Percent Type3 Bisphenol A Epoxy Resin 700 84.2% Huntsman Hardener XB 3086 135 15.2%Total 835 100.0%In other embodiments, the epoxy resin and curative agent ratio may rangefrom, for example, about 84% to about 85% epoxy resin to about 16% toabout 15% curative agent. To lower the cure temperature of an epoxydécor particle, accelerants and/or catalysts such as, for example, aphenolic curative may be incorporated into the composition. Anillustrative phenolic curative has a combining weight of about 100 toabout 500. Other accelerants and/or catalysts compatible with epoxyresins known to those skilled in the art may also be used. Anillustrative cure condition for an epoxy-polyester hybrid décor particleincludes a bake time of about 15 minutes at about 150° C., or less.

The low temperature cure epoxy décor particle composition may includeany desired colorant and/or additive. Illustratively, a low temperaturecure epoxy décor particle composition may include the followingconstituents as shown below in Table No. 3.

TABLE NO. 3 Low Temperature Cure Epoxy Décor Particle Compositions.Approx. Constituent Weight % Bisphenol A Epoxy 48-58 Bisphenol ACurative  9-11 Flow Additive 0.2-3   Degassing Agent 0.2-5   Colorant0.3-40  Filler 10-30

Another illustrative chemistry useful in a décor product is a lowtemperature cure epoxy-polyester hybrid décor particle that has a bindersystem having a low temperature cure epoxy and a polyester resin.Illustrative epoxy resins include the bisphenol A epoxy resins orNovolac epoxy resins described above. An illustrative polyester resinincludes an acid terminated saturated polyester resin. The polyesterresin may have an acid number of between about 75 and about 85. Exampleincludes acid terminated saturated polyesters used as a co-reactant inepoxy-polyester hybrid coating powder formulations. The polyester may besynthesized from neopentyl glycol, terephthalic acid, trimelliticanhydride, and other types of glycols and dibasic organic acids. Thebranched polyesters may have resin functionalities of about 2 to about4, or of about 2.5 to about 3.5 (indicating, that about 2.5 to about 3.5carboxyl groups per polyester molecule). Resin acid numbers may rangefrom about 35 to about 90 with hydroxyl numbers of about 5 to about 10(residual hydroxyl). Acid terminated, saturated polyester resinssuitable for combination with epoxy resins may have an acid number ofabout 70 to about 90, or about 80; a calculated combining weight(combining weight equals 56,100/acid number) of about 625 to about 800,or about 700; a glass transition temperature about 45° C. to about 60°C., or about 55° C.; and/or an ICI cone and plate viscosity of about 15poise to about 50 poise, or about 25 poise, at about 200° C.

To lower the cure temperature of an epoxy-polyester hybrid décorparticle, an accelerant and/or catalyst such as, for example, astannous-organic and/or imidazole-type compound may be incorporated intothe composition. Other accelerants and/or catalysts known to thoseskilled in the art may also be used. An illustrative cure condition foran epoxy-polyester hybrid décor particle includes a bake time of about15 minutes at about 150° C., or less.

Stoichiometric ratios for an epoxy-polyester hybrid décor particle maybe calculated based on the combining weights of resins and curatives.However, as known in the art, molecular structure and chemicalfunctionalities may differ and fluctuate for organic polymer products,making the depiction and calculation of chemical reactions moredifficult and ambiguous than for inorganic chemical reactions.Illustratively, stoichiometric ratios may be calculated based oncombining weights (also referred to as equivalent values) of epoxy andacid-terminated polyester resins. The values of the combining weightsmay be determined by chemical structure (for example, average molecularweight divided by the number of reactive groups, amine values, acidnumbers, etc.). For example, a lower molecular weight type 3 bisphenol Aepoxy resin with an epoxy equivalent weight of 700 and an acidterminated saturated polyester resin with an average number of 80(combining weight of polyester equals 56,100 divided by 80, which equalsapproximately 700), provides a full (100%) stoichiometric calculation asshown below in Table No. 4.

TABLE NO. 4 Full Stoichiometry of an Epoxy-Polyester Hybrid DécorParticle. Epoxy Equivalent Approx. Constituent Weight Percent Type 3Bisphenol A Epoxy Resin 700 50% Acid Terminated Polyester 700 50% Total1400 100.0%  

The low temperature epoxy-polyester hybrid décor particle compositionmay include any desired colorant and/or additive. Illustratively, a lowtemperature cure epoxy-polyester hybrid décor particle composition mayinclude the following constituents as shown below in Table No. 5.

TABLE NO. 5 Low Temperature Cure Epoxy-Polyester Hybrid Décor ParticleCompositions. Approx. Constituent Weight % Bisphenol A Epoxy 29-34SP3320 Hybrid Polyester 29-34 Flow Additive 0.2-3   2-PI (Catalyst)0.2-0.8 Degassing Agent 0.2-5   Colorant 0.3-40  Filler 10-30

Another illustrative chemistry useful in a décor product is a lowtemperature cure polyester-triglycidyl isocyanurate (TGIC) décorparticle. Illustratively, a polyester includes an acid terminatedsaturated polyesters synthesized using, for example, a monomer such astrimethylolpropane, terephthalic acid, neopentyl glycol, adipic acid,hexanediol, 1,4-cyclohexyldimethanol, and isophthalic acid, andpentanediol. The polyesters in one embodiment have resin functionalitiesof about 2.05 to about 2.2 (that is, about 2.05 to about 2.2 carboxylgroups per polyester molecule). The resin acid numbers may range fromabout 20 to about 60, or range on average from about 28 to about 38. Thehydroxyl numbers may range from about 5 to about 10 (residual hydroxyl).TGIC is a trifunctional epoxide resin that is used as a hardener inpolyester-based powder formulations. The combining weight of TGIC is106. Illustratively, an acid terminated, saturated polyester resinssuitable for combination with TGIC in a low temperature curepolyester-TGIC décor particle possess, for example, an acid number about30 to about 40, or about 35; a calculated combining weight (combiningweight equals 56,100 divided by acid number) of about 1,400 to about1,870, or about 1,600; a glass transition temperature about 45° C. toabout 70° C., or about 55° C.; and/or an ICI cone and plate viscosity ofabout 15 poise to about 50 poise, or about 25 poise, at 200° C.

To lower the cure temperature of a polyester-TGIC décor particle, anaccelerant and/or catalyst such as, for example, triphenylethylphosphonium bromide and/or imidazole-type compounds may be incorporatedinto the composition. Other accelerants and/or catalysts known to thoseskilled in the art may also be used. For example, a glycidyl curativechemistries such as aliphatic, cycloaliphatic, aromatic, andmethacrylate based glycidyl compounds with equivalent weights of about50 to about 1,000 and melt temperatures below about 125° C. may byutilized in the low temperature cure polyester-TGIC décor particle. Anillustrative cure condition for a polyester-TGIC décor particle includesa bake time of about 15 minutes at about 135° C.

As mentioned above, molecular structures and chemical functionalitiesmay differ and fluctuate for organic polymer products. Illustratively,stoichiometric ratios are calculated based on the combining weights ofepoxy and acid terminated polyester resins. Values of the combiningweights may be determined from the chemical structure of the respectivecompounds. For example, an acid terminated saturated polyester with anaverage acid number of 35 (combining weight of polyester equals 56,100divided by 35, which equals approximately 1,600) combined with TGIC,provides a full (100%) stoichiometric calculation as shown below inTable No. 6.

TABLE NO. 6 Full Stoichiometry of a Polyester-TGIC Décor Particle. EpoxyEquivalent Approx. Constituent Weight Percent Acid Terminated Polyester1600 93.8% TGIC 106 6.2% Total 1706 100.0%

Due to the large molecular size of the polyester resin and the smallmolecular size and spherical shape of TGIC, a about 10% to about 15%stoichiometric surplus of TGIC may be utilized to achieve, for example,a polyester resin/TGIC ratio of 93/7.

The low temperature polyester-TGIC décor particle composition mayinclude any desired colorant and/or additive. Illustratively, a lowtemperature polyester-TGIC décor particle composition may include thefollowing constituents as shown below in Table No. 7.

TABLE NO. 7 Low Temperature Cure Polyester- TGIC Décor ParticleCompositions. Approx. Constituents Weight % RUCOTE ® 921 Polyester 54-63TGIC 4-5 Flow Additive 0.2-3   Degassing Agent 0.2-5   Colorant 0.3-40 Filler 10-30

An alternative carboxyl polyester resin curative to TGIC includes, forexample, PRIMID® (EMS-Primid, a unit of EMS-Chemie AG). PRIMID® is abeta-hydroxyl alkyl amide curative. However, PRIMID® may require longercure times than a TGIC-based chemistry, as well as a PRIMID® basedcoating may appear slightly more orange than a TGIC-based coating.Pinholes and blistering may also be an issue with the use of a PRIMID®based décor particle where a coating thickness exceeds 4.0 mils.

As mentioned above, a décor product, which includes a décor particle,may include any desired colorant and/or additive. Illustratively, thedécor particle composition may include, for example, a flow additive, adegassing agent, a surfactant or wetting agent, an antioxidant, a heatstabilizer, a ultraviolet light absorber, a wax, a silicone additive, acatalyst, a texturing agent, an electrical charge control agent, anelectrical conductivity agent, a processing aid, a filler, andcombinations thereof.

Flow additives may be utilized in formulating a décor particlecomposition to, for example, reduce or prevent cratering of a finishedcured product and/or to improve flow and leveling. Illustratively, theflow additives may be low molecular acrylic polymers, either in liquidform (for example, a liquid containing about 100% active substance), orin solid form (for example, a solid with about 65% active substance).Examples of flow additives include Acronal 4F (about 100% active, BASF),Byk 363 P (about 65% active, BYK-Chemie), RESIFLOW® P-67 (manufacturedby Estron Chemical), RESIFLOW® PF-67 (about 65% active, EstronChemical), MODAFLOW™ 3 (about 65% active, Monsanto), and POWDERMATE™ 486CFL (about 65% active, Troy Corp.). Illustratively, a flow additive maybe added to a décor particle composition in a range of between about0.3% to about 1% of 100% active flow additive per total formula weightof the décor particle.

A degassing agent may be added to a décor particle composition to, forexample, aid in the evaporation of volatile products within thecomposition during the heating and/or curing cycle to reduce and/orprevent pinholing (volatile bubbles being trapped at the surfaceboundary between the finish and the air). Some degassing agents, such asBenzoin (Velsicol Chemical Corp.), may solvate the resin/curative mixduring the liquid phase of the cure process. Other degassing agents aresurfactant-like and other are wax-like and affect the surface tension ofthe film surface to promote degassing. Illustratively, a décor particlecomposition may contain from about 0.2% to about 2% of active degassingagent per total formula weight of the décor particle. For example, adécor particle that is curable between about 135° C. and about 149° C.(for example a polyester-PRIMID® chemistry), may contain a combinationof about 1% to about 1.8% OXYMELT® A-2 or A-4 (Estron Chemical) andabout 0.2% Benzoin per total formula weight of the décor particle.

A surfactant or wetting agent that may be used in a décor product ordécor particle composition may, for example, promote colorant and/orfiller wetting, and/or improve the flow and/or leveling of a finishedcured product. In addition, a surfactant or wetting agent may promotesubstrate wet-out during the cure reaction, which may improve adhesionand/or corrosion resistance. The addition of surfactants may alsoincrease gloss and distinctness of image of the cured film as well.Illustratively, surfactant levels can range from 0.1% to about 0.5% ofactive substance per total formula weight of the décor particle.Examples of surfactants or wetting agents include cationic, anionicfunctional organic compounds, silane, and polysiloxane, including, forexample, NUOSPERSE™ 657 (manufactured by Elementis Specialties) andSURFYNOL™ 104 S (Air Products and Chemicals, Inc.).

An antioxidant or heat stabilizer may be used in a décor particlecomposition to, for example, inhibit or prevent heat induced yellowingduring the curing and/or heating cycle. Illustratively, an antioxidantor heat stabilizer may be used in a white or relatively light coloreddécor particle composition in an amount from about 0.2% to about 0.5% ofactive substance per total formula weight of the décor particle. More orless antioxidant or heat stabilizer may be used with other colored décorparticles. Examples of antioxidants include Irganox 1076 (Ciba SpecialtyChemicals Corp.) and Irganox B-225 Ciba Specialty Chemicals Corp.). Anexample of a heat stabilizer is Sandostab P-EPQ (Clariant).

An ultraviolet light absorber can be added to a décor particlecomposition to, for example, improve ultraviolet resistance (forexample, weatherability) of a cured finished product. Used incombination with antioxidants and/or heat stabilizers, the performanceof ultraviolet absorbers can be further enhanced.

A wax may be added to a décor particle composition to, for example,control the gloss and/or flow of a cured décor product. A wax may alsobe used to add texturing to a cured décor product. Additionally, somewax additives may improve mar and scratch resistance of a cured décorproduct. Illustratively, a wax from a natural product, such as Carnaubawax, beeswax, hydrocarbon compounds, halogenated hydrocarbons, and PTFEcomprise a large percentage of waxes and may be used in the décorproduct and/or décor particle composition. Examples of wax additivesinclude DT3329-1 (Ciba Geigy), Castor Wax, Powder Tex 61 (ShamrockTechnologies, Inc.), Lanco® TF-1778 (available from Noveon Inc.), andLanco® PP-1362D (available from Noveon, Inc.).

A silicone additive may also be added to a décor particle composition toimprove, for example, mar and scratch resistance of a cured décorproduct. Although not wishing to be held by theory, it is believed thatthe silicone additives reduce the coefficient of friction that mayaffect, for example, intercoat adhesion in a two-coat system. Examplesof silicone additives include polysiloxane and silicone oil.

Catalysts such as 2-Propyl imidazole may be added to a décor particlecomposition to, for example, accelerate cure speed, lower curetemperature, and/or improve physical and/or chemical properties of thecured product.

Texturing agents may be added to a décor particle composition to, forexample, alter and/or manipulate the viscosity of the composition.

Electrical charge control additives may be added to a décor particlecomposition to, for example, control transfer efficiency. Examplesinclude TINUVIN® 144 (Ciba Specialty Chemicals), barium titanate, andquaternary ammonium salts.

Electrical conductivity additives may be added to a décor particlecomposition to, for example, dissipate electrical charge in thecomposition and/or finished product. The electrical conductivityadditives may be, for example, filler-like, pigment-like, or wax-like innature.

Processing aids may be added to a décor particle composition to, forexample, facilitate processing of the composition. Processing aids arewell known to those skilled in the art.

Colorants may be added to a décor particle composition to, for example,obtain a desired color. Illustrative pigments include organic andinorganic pigments, including, for example, titanium dioxide, iron oxidered, iron oxide yellow, iron oxide black, heat stabilized iron oxide,calcinated mixed metal oxide, diarylide, condensated disazo, and phthaloblue. Illustrative colorants and amounts that may be used individuallyor in combination in the décor product and/or décor particle compositionare provided below in Table No. 8.

TABLE NO. 8 Pigments. Approx. Colorant Weight % Titanium Dioxide   1-40Iron Oxide Yellow (C.I. Yellow 14)   2-20 HR-70 Yellow (Organic Pigment)1.5-2 274-0033 (Organic Pigment) 0.3-2 RT-172-D (Organic Pigment) 0.5-5F5RK-A (Organic Pigment)   0.5-3.0 15-1101 AR (Organic Pigment) 0.5-5Iron Oxide Black (C.I. Black 11) 0.5-2 Iron Oxide Red (C.I. Red 101) 1.5-20 Ultra Marine Blue (C.I. Blue 29)   15-25Numerous other organic and inorganic colorants known to those skilled inthe art may be utilized in the compositions herein described.

A filler may also be added to a décor particle composition. Twoillustrative fillers include calcium carbonate and barium sulfate (CaCO₃and BaSO₄, respectively, both manufactured by Fisher Chemicals). Thecalcium carbonate fillers added to the décor product and/or décorparticle compositions may, for example, reduce gloss, as well as theflow of an applied finish at higher concentrations. Wollastonite-typefillers may also be utilized as fillers in the décor product and/ordécor particle compositions. Talcum, clay, dolomite, andmagnesium-aluminum-silicate in powder form, usually ground to 1-10microns average particle size, or micron sized glass beads, may also beused as fillers to obtain specific properties, such as, for example,corrosion resistance, gloss control, and/or film texture.

Illustratively, a décor product is applied to a surface to achieve afilm thickness of about 0.004 mils to about 2.2 mils (about 0.01 micronsto about 56 microns) upon curing of the décor product.

A décor particle formulation such as those embracing low temperaturecure epoxy chemistry, low temperature cure epoxy-polyester hybridchemistry, low temperature cure polyester-TGIC chemistry may be preparedin accordance with the following general processing procedure.

Formulation constituents are dry mixed either through low-intensitytumble-mixing or through high-intensity dry-blending performed in amixer containing a vertical or horizontal mixing shaft with bladesrotating at 50-1,000 rpm. Formulations are low-intensity tumble-mixedfor about 5 to about 20 minutes, for example, or high-intensitydry-mixed for about 1 to about 5 minutes, for example, depending onbatch size. Mixing serves to homogenize the active chemical ingredientsand to disperse inert ingredients for enhanced color consistency and toavoid protrusions in applied films. Batch sizes may range from quarts tokiloliters in size. After dry-blending, the temperature of the mixtureis maintained at or below about 40° C. to prevent lumping or meltdown.

The mixtures are extruded within minutes to hours after dry-mixing.Single screw extruders with reciprocating screw shaft movements, alsocalled co-kneaders, and twin screw extruders with co-rotating screwshafts are suitable extruders, as well as planetary extruders,counter-rotating twin screw extruders, or single screw extruders.Illustrative extruder size ranges from table-top laboratory models with10-30 mm screw diameters and 1-5 kg per hour theoretical outputs toproduction models with 30 to over 300 mm screw diameters and 100 kg toover 2,000 kg per hour theoretical outputs.

The extruders for processing may be heated via water, oil, or electricalheat jacket located on the outside of the extruder barrels. Extruderbarrel processing temperatures may range from about 70° C. to about 125°C., though temperatures outside this range may be used to achievedesired properties in some applications. Some extruder barrel heatersutilized in the powder processing may be segmented, in which case, thepremix intake zone of the extruder may be run cold or at a minimal heatof about 40° C. to about 50° C. Depending on extruder and screw design,a barrel heat of about 100° C.±15° C. is adequate for processinghighly-reactive, low temperature cure powder coating formulas. Thescrews may have a helical section in the premix intake area and “paddle”sections for dispersing and melt-mixing the extrudate. Residence time ofthe extrudate within the extruder typically does not exceed about 60seconds. The production extruders used for processing the powdercoatings are run between about 50 and about 750 rpm screw speed. Screwspeeds and extruder barrel temperatures are selected to obtain betweenabout 50% to about 90% torque. Extrudate temperatures range from about100° C. to about 125° C. as a result of extruder barrel heat andfrictional heat from the rotating screws. The extrudate is immediatelycooled after exiting the extruder to solidify the material for furtherprocessing and to arrest chemical reactions. The extrudate isgravity-fed into counter-rotating chill rolls set about 1.5 to about 3mm apart. The resulting extrudate sheet is transported on a cooling beltto a flaker or crusher unit where the sheet is broken into flakes underabout 1 inch square in size. Cooling belt temperatures from about 5° C.to about 35° C. are maintained during processing. The resulting flakesare milled and characterized using air classifying mills (ACM),cyclones, and sieves, to determine particle size distributions and meanparticle sizes. Illustratively, a particle size distribution for a décorparticle ranges from about 90% by volume or more of the particles havinga size less than about 100 microns, or less than about 25 microns, orless than about 10 microns, or from about 0.1 to about 50 microns, orfrom about 1 to about 20 microns, or from about 3 to about 10 microns,or from greater than about 750 nm to about 100 microns, or larger orsmaller particle sizes depending on the desired application. Allequipment is purged after processing different formulas or colors toavoid chemical or color cross-contamination.

An emulsified décor product may be prepared in accordance with thefollowing general processing procedure. In a one-gallon glass container,initially an emulsifier is added to a powder, such as a NATURA™ tonerand/or a décor particle and mixed to thoroughly coat the powder with theemulsifier. Water is then added to the powder and emulsifier mixture andis blended using an IKA-Werke Eurostar power basic mixer at a speed ofabout 750 rpm for about 4 hours. Additional additives may be added if sodesired at any point during preparation of the décor product. After the4 hour blending period, the mixture is further mixed by continuouslymixing at room temperature on an magnetic stir/heat plate (Isotemp#409N0063 available from Fisher-Scientific) with a 2-inch magnetic stirbar at 100 rpm for an additional 24 hours. Illustratively, an emulsifieddécor product composition may include the following constituents asshown below in Table No. 9.

TABLE NO. 9 Emulsified Décor Product Composition. Approx. ConstituentsWeight % Water   70-97 Surfactant 0.1-5 Powder  1.1-40 Adhesive   0-10Additive 0.1-5

The present disclosure is further illustrated by the following examples,which should not be construed as limiting in any way. Unless otherwisestated, all percentages recited in these examples are weight percentsbased on total specified composition weight.

EXAMPLES

The décor particle compositions of examples 1-24 were prepared using thegeneral processing procedure described above by blending (mixing) andprocessing the constituents on a 19 mm APV laboratory twin screwextruder (Model No. MP19TC-25, manufactured by Baker Perkins) withco-rotating screws at 100° C. barrel temperature, 400 rpm screw speed,and 50% to 90% torque. The extrudate was cooled on chill rolls thatresulted in 3/32 inch (about 3 mm) thick solid extrudate sheets. Thesheets were broken into flakes no larger than 1 square inch (6.45 cm²)in size. The flakes were ground on air-cooled jet mills and classifiedto a particle size range of about 0 microns to about 20 microns. Thedécor products of examples 25-28 was prepared using the generalprocessing procedure described above by mixing the décor particle ortoner and emulsifier for a period of time until the décor particles ortoner were coated with the emulsifying agent or agents. Water was thenadded and thoroughly mixed as described above.

In the composition of Table Nos. 10-25, the trademark KUKDO® KD-242G(manufactured by Kukdo Chemical Co., LTD) is a type 3 bisphenol-A epoxyresin with an epoxy equivalent weight of about 700 g/eq. In thecomposition of Table Nos. 10-17, Huntsman Hardener XB 3086 (manufacturedby Huntsman Advanced Materials) is a proprietary phenolic curativecontaining phenol, 4,4′-(1-methylethylidene)bis-, polymer with2,2′-[(1-methylethylidene)bis(4,1-phenyleneoxymethylene)]bis[oxirane](commonly described as a polymer of epoxy resin and bisphenol A), aconfidential accelerator, and phenol, 4,4′-(1-methylethylidene)bis-(commonly known as bisphenol A). In the composition of Table Nos. 18-25,Actiron NXJ-60 (manufactured by Advanced Technology & Industrial Co.) isa 2-propylimidazole catalyst. In the composition of Table Nos. 10-13,18-21, and 26-29, the trademark TI-PURE® TiO₂ R-960 (manufactured byE.I. du Pont de Nemours and Company) is a titanium oxide white pigment.In the composition of Table Nos. 11-12, 14-15, 19-20, 22-23, 27, and30-31, Y 10M (CAS. No. 51274-00-1, manufactured by ABCR) is an ironoxide yellow pigment. In the composition of Table Nos. 11, 19, and27-29, 274-0033 (CAS No. 5468-75-7, manufactured by ABCR) is a yellowpigment having the chemical formula of2,2′-((3,3′-dichloro(1,1′-biphenyl)-4,4′-diyl)bis(azo))bis(N-(2-M-ethylphenyl)-3-oxobutyramide).In the composition of Table Nos. 11, 19, and 27, HR-70 Yellow(manufactured by Clariant) is a yellow organic pigment. In thecompositions of Table Nos. 26-33 the trademark RUCOTE® 921 polyester(manufactured by Bayer Material Science, LLC) is a low viscositycarboxyl functional polyester having an acid value of 38 mg KOH/g, ahydroxyl number 6 mg KOH/g, a viscosity of 1800 ICI cone and plate at200° C./cPs, and a Tg of 60° C.

Example 1 Preparation of a White Low Temperature Cure Epoxy DécorParticle

A white low temperature cure epoxy-based décor particle having thecomposition shown in Table No. 10 below was prepared in the mannerdescribed above.

TABLE NO. 10 White Low Temperature Cure Epoxy Composition. Constituents(wt %) KD-242G Epoxy 48 Huntsman Hardener XB 3086 10 P-67 1 Oxymelt A-21 TiO₂ R-960 40

Example 2 Preparation of a Yellow Low Temperature Cure Epoxy DécorParticle

A yellow low temperature cure epoxy-based décor particle having thecomposition shown in Table No. 11 below was prepared in the mannerdescribed above.

TABLE NO. 11 Yellow Low Temperature Cure Epoxy Décor ParticleComposition. Constituents (wt %) KD-242G Epoxy 49 Huntsman Hardener XB3086 11 P-67 1 Oxymelt A-2 1 TiO₂ R-960 20 Y 10M Iron Oxide YellowPigment 4 274-0033 2.2 HR-70 Yellow Pigment 1.8 BaSO₄ 10

Example 3 Preparation of a Red Low Temperature Cure Epoxy Décor Particle

A red low temperature cure epoxy-based décor particle having thecomposition shown in Table No. 12 below was prepared in the mannerdescribed above.

TABLE NO. 12 Red Low Temperature Cure Epoxy Décor Particle Composition.Constituents (wt %) KD-242G Epoxy 48.5 Huntsman Hardener XB 3086 10.3P-67 1 Oxymelt A-2 1.04 TiO₂ R-960 5.13 Y 10M Iron Oxide Yellow Pigment0.03 RT-172-D Pigment 2.5 F5RK-A Pigment 1.5 BaSO₄ 30

Example 4 Preparation of a Blue Low Temperature Cure Epoxy DécorParticle

A blue low temperature cure epoxy-based décor particle having thecomposition shown in Table No. 13 below was prepared in the mannerdescribed above.

TABLE NO. 13 Blue Low Temperature Cure Epoxy Décor Particle Composition.Constituents (wt %) KD-242G Epoxy 49.25 Huntsman Hardener XB 3086 10.75P-67 1 Oxymelt A-2 1.05 TiO₂ R-960 15. 15-1101 A4R Pigment 2.5 BK 50990.45 BaSO₄ 20

Example 5 Preparation of a Brown Low Temperature Cure Epoxy DécorParticle

A brown low temperature cure epoxy-based décor particle having thecomposition shown in Table No. 14 below was prepared in the mannerdescribed above.

TABLE NO. 14 Brown Low Temperature Cure Epoxy Décor ParticleComposition. Constituents (wt %) KD-242G Epoxy 51.67 Huntsman HardenerXB 3086 9.13 P-67 1 Oxymelt A-2 1 TiO₂ RCL-6 1.18 Y 10M Iron OxideYellow Pigment 2.54 BK 5099 2 RO 8097 1.48 BaSO₄ 30

Example 6 Preparation of an Iron Oxide Yellow Low Temperature Cure EpoxyDécor Particle

An iron oxide yellow low temperature cure epoxy-based décor particlehaving the composition shown in Table No. 15 below was prepared in themanner described above.

TABLE NO. 15 Iron Oxide Yellow Low Temperature Cure Epoxy Décor ParticleComposition. Constituents (wt %) KD-242G Epoxy 57.8 Huntsman Hardener XB3086 10.2 P-67 1 Oxymelt A-2 1 Y 10M Iron Oxide Yellow Pigment 20 BaSO₄10

Example 7 Preparation of a Iron Oxide Red Low Temperature Cure EpoxyDécor Particle

An iron oxide red low temperature cure epoxy-based décor particle havingthe composition shown in Table No. 16 below was prepared in the mannerdescribed above.

TABLE NO. 16 Iron Oxide Red Low Temperature Cure Epoxy Décor ParticleComposition. Constituents (wt %) KD-242G Epoxy 57.8 Huntsman Hardener XB3086 10.2 P-67 1 Oxymelt A-2 1 RO 8097 20 BaSO₄ 10

Example 8 Preparation of an Ultra Marine Blue Low Temperature Cure EpoxyDécor Particle

An ultra marine blue low temperature cure epoxy-based décor particlehaving the composition shown in Table No. 17 below was prepared in themanner described above.

TABLE NO. 17 Ultra Marine Blue Low Temperature Cure Epoxy Décor ParticleComposition. Constituents (wt %) KD-242G Epoxy 57.8 Huntsman Hardener XB3086 10.2 P-67 1 Oxymelt A-2 1 UMB-304 20 BaSO₄ 10

Example 9 Preparation of a White Low Temperature Cure Epoxy-PolyesterHybrid Décor Particle

A white low temperature cure epoxy-polyester hybrid décor particlehaving the composition shown in Table No. 18 below was prepared in themanner described above.

TABLE NO. 18 White Low Temperature Cure Epoxy-Polyester Hybrid DécorParticle Composition. Constituents (wt %) KD-242G Epoxy 28.5 SP 3320Hybrid Polyester 29 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1 TiO₂ R-96040

Example 10 Preparation of a Yellow Low Temperature Cure Epoxy-PolyesterHybrid Décor Particle

A yellow low temperature cure epoxy-polyester hybrid décor particlehaving the composition shown in Table No. 19 below was prepared in themanner described above.

TABLE NO. 19 Yellow Low Temperature Cure Epoxy-Polyester Hybrid DécorParticle Composition. Constituents (wt %) KD-242G Epoxy 29.75 SP 3320Hybrid Polyester 29.75 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1 TiO₂R-960 20 Y 10M Iron Oxide Yellow Pigment 4 274-0033 Pigment 2.2 HR-70Yellow Pigment 1.8 BaSO₄ 10

Example 11 Preparation of a Red Low Temperature Cure Epoxy-PolyesterHybrid Décor Particle

A red low temperature cure epoxy-polyester hybrid décor particle havingthe composition shown in Table No. 20 below was prepared in the mannerdescribed above.

TABLE NO. 20 Red Low Temperature Cure Epoxy-Polyester Hybrid DécorParticle Composition. Constituents (wt %) KD-242G Epoxy 29.15 SP 3320Hybrid Polyester 29.15 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1.04 TiO₂R-960 5.13 Y 10M Iron Oxide Yellow Pigment 0.03 RT-172-D Pigment 2.5F5RK-A Pigment 1.5 BaSO₄ 30

Example 12 Preparation of a Blue Low Temperature Cure Epoxy-PolyesterHybrid Décor Particle

A blue low temperature cure epoxy-polyester hybrid décor particle havingthe composition shown in Table No. 21 below was prepared in the mannerdescribed above.

TABLE NO. 21 Blue Low Temperature Cure Epoxy-Polyester Hybrid DécorParticle Composition. Constituents (wt %) KD-242G Epoxy 29.75 SP 3320Hybrid Polyester 29.75 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1.05 TiO₂R-960 15 15-1101 A4R Pigment 2.5 BK 5099 0.45 BaSO₄ 20

Example 13 Preparation of a Brown Low Temperature Cure Epoxy-PolyesterHybrid Décor Particle

A brown low temperature cure epoxy-polyester hybrid décor particlehaving the composition shown in Table No. 22 below was prepared in themanner described above.

TABLE NO. 22 Brown Low Temperature Cure Epoxy-Polyester Hybrid DécorParticle Composition. Constituents (wt %) KD-242G Epoxy 30.1 SP 3320Hybrid Polyester 30.2 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1 TiO₂ RCL-61.18 Y 10M Iron Oxide Yellow Pigment 2.54 BK 5099 2 RO 8097 1.48 BaSO₄30

Example 14 Preparation of an Iron Oxide Yellow Low Temperature CureEpoxy-Polyester Hybrid Décor Particle

An iron oxide yellow low temperature cure epoxy-polyester hybrid décorparticle having the composition shown in Table No. 23 below was preparedin the manner described above.

TABLE NO. 23 Iron Oxide Yellow Low Temperature Cure Epoxy- PolyesterHybrid Décor Particle Composition. Constituents (wt %) KD-242G Epoxy33.75 SP 3320 Hybrid Polyester 33.75 P-67 1 Actiron NXJ-60 0.5 OxymeltA-2 1 Y 10M Iron Oxide Yellow Pigment 20 BaSO₄ 10

Example 15 Preparation of an Iron Oxide Red Low Temperature CureEpoxy-Polyester Hybrid Décor Particle

An iron oxide red low temperature cure epoxy-polyester hybrid décorparticle having the composition shown in Table No. 24 below was preparedin the manner described above.

TABLE NO. 24 Iron Oxide Red Low Temperature Cure Epoxy- Polyester HybridDécor Particle Composition. Constituents (wt %) KD-242G Epoxy 33.75 SP3320 Hybrid Polyester 33.75 P-67 1 Actiron NXJ-60 0.5 Oxymelt A-2 1 RO8097 20 BaSO₄ 10

Example 16 Preparation of an Ultra Marine Blue Low Temperature CureEpoxy-Polyester Hybrid Décor Particle

An ultra marine blue temperature cure epoxy-polyester hybrid décorparticle having the composition shown in Table No. 25 below was preparedin the manner described above.

TABLE NO. 25 Ultra Marine Blue Low Temperature Cure Epoxy- PolyesterHybrid Décor Particle Composition. Constituents (wt %) KD-242G Epoxy33.75 SP 3320 Hybrid Polyester 33.75 P-67 1 Actiron NXJ-60 0.5 OxymeltA-2 1 UMB-304 20 BaSO₄ 10

Example 17 Preparation of a White Low Temperature Cure Polyester-TGICDécor Particle

A white low temperature cure polyester-TGIC décor particle having thecomposition shown in Table No. 26 below was prepared in the mannerdescribed above.

TABLE NO. 26 White Low Temperature Cure Polyester- TGIC Décor ParticleComposition. Constituents (wt %) Rucote 921 Polyester 54 TGIC 4 P-67 1Oxymelt A-2 1 TiO₂ R-960 40

Example 18 Preparation of a Yellow Low Temperature Cure Polyester-TGICDécor Particle

A yellow low temperature cure polyester-TGIC décor particle having thecomposition shown in Table No. 27 below was prepared in the mannerdescribed above.

TABLE NO. 27 Yellow Low Temperature Cure Polyester- TGIC Décor ParticleComposition. Constituents (wt %) Rucote 921 Polyester 55.75 TGIC 4.25P-67 1 Oxymelt A-2 1 TiO₂ R-960 20 Y 10M Iron Oxide Yellow Pigment 4274-0033 Pigment 2.2 HR-70 Yellow Pigment 1.8 BaSO₄ 10

Example 19 Preparation of a Red Low Temperature Cure Polyester-TGICDécor Particle

A red low temperature cure polyester-TGIC décor particle having thecomposition shown in Table No. 28 below was prepared in the mannerdescribed above.

TABLE NO. 28 Red Low Temperature Cure Polyester- TGIC Décor ParticleComposition. Constituents (wt %) Rucote 921 Polyester 54.6 TGIC 4.2 P-671 Oxymelt A-2 1.04 TiO₂ R-960 5.13 274-0033 Pigment 0.03 RT-172-D 2.5F5RK-A 1.5 BaSO₄ 30

Example 20 Preparation of a Blue Low Temperature Cure Polyester-TGICDécor Particle

A blue low temperature cure polyester-TGIC décor particle having thecomposition shown in Table No. 29 below was prepared in the mannerdescribed above.

TABLE NO. 29 Blue Low Temperature Cure Polyester- TGIC Décor ParticleComposition. Constituents (wt %) Rucote 921 Polyester 55.75 TGIC 4.25P-67 1 Oxymelt A-2 1.05 TiO₂ R-960 15 274-0033 Pigment 0.03 15-1101 A4RPigment 2.5 BK 5099 0.45 BaSO₄ 20

Example 21 Preparation of a Brown Low Temperature Cure Polyester-TGICDécor Particle

A brown low temperature cure polyester-TGIC décor particle having thecomposition shown in Table No. 30 below was prepared in the mannerdescribed above.

TABLE NO. 30 Brown Low Temperature Cure Polyester- TGIC Décor ParticleComposition. Constituents (wt %) Rucote 921 Polyester 56.5 TGIC 4.3 P-671 Oxymelt A-2 1 TiO₂ RCL-6 1.18 Y 10M Iron Oxide Yellow Pigment 2.54 BK5099 2 RO 8097 1.48 BaSO₄ 30

Example 22 Preparation of an Iron Oxide Yellow Low Temperature CurePolyester-TGIC Décor Particle

An iron oxide yellow low temperature cure polyester-TGIC décor particlehaving the composition shown in Table No. 31 below was prepared in themanner described above.

TABLE NO. 31 Iron Oxide Yellow Low Temperature Cure Polyester- TGICDécor Particle Composition. Constituents (wt %) Rucote 921 Polyester63.3 TGIC 4.7 P-67 1 Oxymelt A-2 1 Y 10M Iron Oxide Yellow Pigment 20BaSO₄ 10

Example 23 Preparation of an Iron Oxide Red Low Temperature CurePolyester-TGIC Décor Particle

An iron oxide red low temperature cure polyester-TGIC décor particlehaving the composition shown in Table No. 32 below was prepared in themanner described above.

TABLE NO. 32 Iron Oxide Red Low Temperature Cure Polyester- TGIC DécorParticle Composition. Constituents (wt %) Rucote 921 Polyester 63.3 TGIC4.7 P-67 1 Oxymelt A-2 1 RO 8097 20 BaSO₄ 10

Example 24 Preparation of a Ultra Marine Blue Low Temperature CurePolyester-TGIC Décor Particle

An ultra marine blue temperature cure polyester-TGIC décor particlehaving the composition shown in Table No. 33 below was prepared in themanner described above.

TABLE NO. 33 Ultra Marine Blue Low Temperature Cure Polyester- TGICDécor Particle Composition. Constituents (wt %) Rucote 921 Polyester63.3 TGIC 4.7 P-67 1 Oxymelt A-2 1 UMB-304 20 BaSO₄ 10

Example 25 Preparation of a Blue Low Temperature Cure Epoxy DécorProduct

A blue low temperature cure epoxy-based décor product having thecomposition shown in Table No. 34 below was prepared in the mannerdescribed above.

TABLE NO. 34 Blue Low Temperature Cure Epoxy Décor Product Composition.Constituents (wt %) Water 96.85 ALCOPRINT ™ PTU 0.15 Composition ofTable No. n13 3

Example 26 Preparation of a Blue Low Temperature Cure Epoxy-PolyesterHybrid Décor Product

A blue low temperature cure epoxy-polyester hybrid décor product havingthe composition shown in Table No. 35 below was prepared in the mannerdescribed above.

TABLE NO. 35 Blue Low Temperature Cure Epoxy-Polyester Hybrid DécorProduct Composition. Constituents (wt %) Water 96.85 ALCOPRINT ™ PTU0.15 Composition of Table No. 21 3

Example 27 Preparation of a Blue Low Temperature Cure Polyester-TGICDécor Product

A blue low temperature cure polyester-TGIC décor product having thecomposition shown in Table No. 36 below was prepared in the mannerdescribed above.

TABLE NO. 36 Blue Low Temperature Cure Polyester- TGIC Décor ProductComposition. Constituents (wt %) Water 96.85 ALCOPRINT ™ PTU 0.15Composition of Table No. 29 3

Example 28 Preparation of a Blue Low Temperature Cure NATURA® BasedDécor Product

A blue low temperature cure NATURA® based décor product having thecomposition of shown in Table No. 37 below, was prepared in the mannerdescribed above. Blue (cyan) NATURA® toner and clear NATURA® toner fromSawgrass Technologies, Inc. were purchased from ACP Technologies (I.D.Nos. 127 and 131, respectively).

TABLE NO. 37 Blue Low Temperature NATURA ® Based Décor Product.Constituents (wt %) Water 96.85 ALCOPRINT ™ PTU 0.15 Blue NATURA ® Toner1.5 Clear NATURA ® Toner 1.5

Example 29 Application, Affixation, Reversibility, and Durability of theDécor Products of Examples 25-28 on a Soft Surface

Décor products of the present disclosure were tested for the ability tobe applied to a nylon test carpet, removal (reversibility) from thenylon test carpet prior to an affixation step, affixation to the nylontest carpet using heat as the energy source, and durability afteraffixation to the nylon test carpet.

The four individual décor products of Examples 25-28 were thoroughlymixed and individually placed into 8 oz. PET bottles with finger pumpfine mist sprayers having an output of 60 micron particle size(N2862524410WHT3, bottle neck—24/410; available from ebottles.com,Inc.). Four two-foot by two-foot pieces of nylon test carpet werevacuumed using a Bissell CLEANVIEW® II vacuum cleaner manufactured byBissell Homecare, Inc. to remove loose fibers and dirt. Thespecifications of the nylon test carpet utilized are indicated in Table38.

TABLE 38 Nylon Test Carpet and Polyester Test Carpet Specifications.Nylon Test Carpet Polyester Test Carpet Style 7522 Favored One SP501Manufacturer Mohawk Industries Mohawk Industries Pile Yarn ContentFilament 100% Nylon Spun 100% Polyester Yarn Twists per inch 4.25 × 4.255.0 × 4.8 Fabric Type Cut Pile Cut Pile Fiber Treatment Ultrastrand withMohawk APP soil & stain Polyester W/SGC Gauge 5/32 ⅛ C Pile Height 0.4850.440 Stitches per inch 7.83 8.50 Certified Pile Weight 25.20 oz. 39.50oz. Total Weight 56.29 oz. 71.03 oz. Density 1871 3232 Dye MethodFluidye Beck Primary Backing Woven Polypropylene Woven PolypropyleneSecondary Backing Woven Polypropylene Woven Polypropylene PerformanceAppearance 3.50 3.25 Retention Rating

For each of the four pieces of nylon test carpet, the baseline color ofeach of three spots over which a respective décor product was appliedwas determined using a Minolta data processor model No. DP-301 combinedwith a Minolta model No. CR-310 chroma meter (both manufactured byKonica Minolta Sensing Americas, Inc.) that was set to the “L-a-b”setting to record Δ E (color change) and calibrated according to themanufacturer's instructions.

The following tests were performed separately for each of the four décorproducts of Examples 25-28. Prior to application of the décor product, astencil made of a disposable absorbent material available fromKimberly-Clark Corp. with a nylon mesh backing was centered on thesurface of the nylon test carpet sample. Subsequently, the décor productwas applied as a gentle mist to the nylon test carpet from the fingersprayer at distance of 8-10 inches from the nylon test carpet and at arate to saturate the top surface of the nylon test carpet. The applieddécor product was allowed to dry overnight at ambient temperature andhumidity on the nylon test carpet. Once dried one half of the applieddécor product pattern was removed from the nylon test carpet using aShop-Vac® 1×1® wet/dry vacuum with hose attachment (1¼ inch diameter×4feet). The vacuum characteristics include 1 peak horsepower, 115 cubicfeet/minute of air flow, 52 inches of sealed pressure, and electricalratings of 120 V, 60 Hz, and 5.5 A. The pattern was vacuumed twentytimes in one direction and then twenty times in the opposite directionover the same area. Once vacuumed, L-a-b measurements were taken fromthe vacuumed areas of the nylon test carpet with the Minolta dataprocessor and Minolta chroma meter.

The un-vacuumed décor product pattern was subsequently affixed on thenylon test carpet by placing an absorbent paper towel (WYPALL® X60reinforced wipes from Kimberly-Clark Corp.) over the décor productpattern and heating the décor product pattern using a household iron(Hamilton-Beach Model #14340) set at the highest setting (cotton). Heatwas applied through the absorbent paper towel in a circular motion for2½ minutes per square ft of décor product. Subsequently, the paper towelwas removed from the nylon test carpet and L-a-b values were measured onthe affixed décor product pattern using the Minolta data processor andMinolta chroma meter specified above.

To determine the resilience of the affixed décor product on the nylontest carpet, one half of the affixed décor product was vacuumed twentytimes (using a back and forth motion) with a Shop-Vac® 1×1® wet/dryvacuum with hose attachment. The L-a-b values of the vacuumed andaffixed versus the affixed-only (unvacuumed) areas were taken usingMinolta data processor combined with a Minolta chroma meter as mentionedabove.

Reversibility, affixation, and durability of the décor products ofExamples 25-28 are shown below in Table Nos. 39-42.

TABLE NO. 39 Reversibility, Affixation, and Durability of the Blue LowTemperature Cure Epoxy Décor Product of Example 25. L a b ΔE Initial55.54 4.72 11.28 — Application 45.53 4.83 −15.43 28.52 Reversibility51.48 4.64 9.94 4.28 Affixation 39.11 2.51 −7.66 25.17 Durability(vacuumed) 41.89 1.99 −6.38 22.49 Durability (not vacuumed) 37.09 2.55−8.66 27.25

TABLE NO. 40 Reversibility, Affixation, and Durability of the Blue LowTemperature Cure Epoxy-Polyester Hybrid Décor Product of Example 26. L ab ΔE Initial 53.05 5.01 11.52 — Application 47.00 4.19 −4.35 17.00Reversibility 50.63 4.99 10.52 2.62 Affixation 44.01 3.31 0.39 14.44Durability (vacuumed) 45.73 3.11 0.70 13.20 Durability (not vacuumed)42.72 3.67 −0.20 15.68

TABLE NO. 41 Reversibility, Affixation, and Durability of the Blue LowTemperature Cure Polyester-TGIC Décor Product of Example 27. L a b ΔEInitial 54.85 4.78 11.23 — Application 47.17 4.47 −10.84 23.37Reversibility 51.47 4.78 10.48 3.46 Affixation 43.19 3.37 −7.45 22.07Durability (vacuumed) 42.06 3.27 −6.38 21.82 Durability (not vacuumed)42.51 3.50 −5.60 20.91

TABLE NO. 42 Reversibility, Affixation, and Durability of the Blue LowTemperature NATURA ® Based Décor Product of Example 28. L a b ΔE Initial54.95 4.79 11.31 — Application 42.72 1.58 −11.09 25.72 Reversibility50.89 4.70 11.37 4.06 Affixation 38.45 −3.01 −10.75 28.63 Durability(vacuumed) 37.05 −2.80 −8.62 27.84 Durability (not vacuumed) 38.23 −2.63−10.17 28.21

Example 30 Determination of Glass Transition Temperatures (Tg) andMelting Temperatures (Tm) of Surface Substrates

Tg and Tm of surface substrates were measured using a Model Q100Differential Scanning Calorimeter (TA Instruments, Inc.) at a heatingrate of 20° C./min. Specifically, in this way, the nylon carpet of TableNo. 38 was measured to have a Tg of 40-45° C. and a Tm of 257° C.Further, a polyester carpet of Table No. 38 was measured to have a Tg of140-150° C. and a Tm of 247° C.

INDUSTRIAL APPLICATION

The method disclosed herein allows for the application of a décorproduct to be applied to a surface, and more specifically a soft surfacesuch as a carpet, a rug, draperies, curtains, upholstery, and the like.By applying the décor product to the soft surface, perceived aestheticquality of the soft surface is improved and may extend the useful lifeof the soft surface before need for replacement.

The disclosure has been presented in an illustrative manner in order toenable a person of ordinary skill in the art to make and use thedisclosure, and the terminology used is intended to be in the nature ofdescription rather than of limitation. It is understood that thedisclosure may be practiced in ways other than as specificallydisclosed, and that all modifications, equivalents, and variations ofthe present disclosure, which are possible in light of the aboveteachings and ascertainable to a person of ordinary skill in the art,are specifically included within the scope of the impending claims. Allpatents, patent publications, and other references cited herein areincorporated herein by reference in their entirety.

1. A décor product composition, comprising: an interactive sensoryelement; and a décor particle comprising a homogeneous mixture of afirst additive and a polymer selected from the group consisting of apolyolefin, a polyurethane, an acrylic, an acrylate, a polyacrylate, apolyamine, a polyamide, a polyamid, a polyimide, a polyether, apolystyrene, a polycarbonate, a polysulfone, a polyester, apolyalkyleneoxide, a polysiloxane, a polysulfide, a polyethyleneimine, apolyglycoside, a cellulose, a wax, a paraffin, a phenolic, an elastomer,a vinyl, a hot melt adhesive, a hydrophilic polycarbodiimide, apolysaccharide aldehyde derivative, a bismaleimides, a silicon, a soyaoil, a linseed oil modified alkyd, a copolymer, a homopolymer, andmixtures thereof; an optional second additive; and a liquid carrier,wherein the first or the second additive comprises at least one of acolorant, a surfactant, a curative, a flow additive, an odor eliminatingagent, an odor absorbing agent, a bactericide, a miticide, aninsecticide, a pesticide, or a fungicide.
 2. The décor productcomposition of claim 1, wherein the polymer is soluble in at least oneof a hydrocarbon, an alcohol, a glycol ether, a nitrated solvent, achlorinated solvent, a ketone, an ether, an ester, an amine, benzylacetate, a phenol, a polyvinyl alcohol, an organic sulfone, and asulfoxide.
 3. The décor product composition of claim 2, wherein thepolymer is selected from the group consisting of a polyolefin, apolycarbonate, a polysulfone, a polyester, a vinyl, and a polyamide. 4.The décor product composition of claim 3, wherein the polymer is apolyester.
 5. The décor product composition of claim 1, wherein theinteractive sensory element comprises an olfactory effect or a virtualcolorant that comprises at least one of a phosphorescent compound or afluorescent compound.
 6. The décor product composition of claim 5,wherein the olfactory effect comprises a fragrance emitter, adeodorizer, or an odiferous pet barrier.
 7. The décor productcomposition of claim 1 further comprising a temporal emission agent. 8.The décor product composition of claim 1 further comprising a bioactiveagent selected from the group consisting of a bactericide, a miticide,an insecticide, a pesticide, and a fungicide.
 9. A method for applying adesign to a surface, the method comprising: applying the décor productcomposition of claim 1 to a surface; allowing the décor productcomposition to substantially dry on the surface; and applying heat or achemical to the décor product composition to durably affix the décorproduct composition to the surface.
 10. A liquid-based décor productcomposition, comprising: a colorant mixed with an adherent compoundcomprising at least one of a thermoplastic polymer or a thermosetpolymer; an additive; and an interactive sensory element comprising atleast one of an illuminating effect or an olfactory effect, wherein theadherent compound is soluble in at least one of a hydrocarbon, analcohol, a glycol ether, a nitrated solvent, a chlorinated solvent, aketone, an ether, an ester, an amine, benzyl acetate, a phenol, apolyvinyl alcohol, an organic sulfone, and a sulfoxide.
 11. The décorproduct composition of claim 10 further comprising a virtual colorantcomprising at least one of a phosphorescent or a fluorescent compound.12. The décor product composition of claim 10, wherein the additivecomprises at least one of a surfactant, an odor eliminating agent, anodor absorbing agent, a bactericide, a miticide, an insecticide, apesticide, or a fungicide.
 13. The décor product composition of claim 10further comprising particles, wherein particles comprise a homogeneousmixture of the colorant and the adherent compound.
 14. The décor productcomposition of claim 13, wherein about 90% by volume or more of theparticles have a size of less than about 100 microns.
 15. A method ofapplying an interactive sensory element to a surface, the methodcomprising: applying the décor product composition of claim 10 to thesurface; allowing the décor product composition to substantially dry onthe surface; and applying a chemical to the décor product composition todurably affix the décor product composition to the surface.
 16. A décorproduct for imparting a colorant to a surface, comprising: a firstlayer; a support layer disposed on the first layer and comprising anadherent compound; and a décor product composition associated with thesupport layer, the décor product composition comprising an optionalinteractive sensory element and particles comprising a colorant and apolymer, wherein the adherent compound at least one of: 1) temporarilyadheres the particles to the first layer; 2) temporarily adheres theparticles to the surface; and 3) permanently adheres the particles tothe surface.
 17. The décor product composition of claim 16, wherein theadherent compound comprises at least one of a pressure-sensitiveadhesive, a water soluble polymer, a water-soluble transparent film, atemporary adhesive, and a polymeric resin.
 18. The décor productcomposition of claim 16, wherein the particles comprise a homogeneousmixture of the colorant and the polymer.
 19. A method of imparting acolor to a surface, comprising: placing the décor product of claim 16 onthe surface; temporarily adhering the décor product to the surface; andapplying pressure or a liquid to the décor product to permanently adherethe particles to the surface to impart a color thereon.
 20. The methodof claim 19, wherein the liquid comprises water, a hydrocarbon, analcohol, a glycol ether, a nitrated solvent, a chlorinated solvent, aketone, an ether, an ester, an amine, benzyl acetate, a phenol, apolyvinyl alcohol, an organic sulfone, or a sulfoxide.